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Reference Guide
Contents
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5 Product Blender
Product Blender: Theory
Adding a Product Blender
Optimizing the Product Stream
Selecting the Calculation Model
ProductBlender Property View
Specify Product Blender Connections
Specifying Parameters
Product Blender Optimization Tab
Configuring the Optimization Parameters
Adding Variables to the Optimization Calculation
6 Catalytic Reformer
Typical Catalytic Reformer Configurations
Catalytic Reformer Technical Background
Catalytic Reformer Kinetic Lumps
Feed Characterization System
Catalytic Reformer Reaction Kinetics
Adding a Catalytic Reformer
Creating a Catalytic Reformer Template
Reformer Configuration Wizard
Configuration (Page 1 of 3)
Geometry Page 2 of 3
Calibration Factors Page 3 of 3
Catalytic Reformer Property View
Design Tab
Configuring the Reactor Section
Configuring the Stabilizer Tower
Viewing Catalytic Reformer Results
Catalytic Reformer Environment
Reactor Section Property View
Configuring Reactor Design
Specifying Feed Type
Specifying Operation Details
Results Tab
Calibration Environment
Running Pre-Calibration for the Catalytic Reformer
Calibrating the Catalytic Reformer
Validation Wizard Property View
Factor Set Property View
Averaging Calibration Factor Sets
Calibration Set Library Property View
Selecting Calibration Factor Sets
Reactor Parameters
Advanced Options
Stabilizer Parameters
Select Data Sets for Calibration Property View
Data Set Manager Property View
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Hydroprocessor Bed in EO
Tuning the HBED
Adding a Hydroprocessor Bed
HBEDProperty View
HBEDSimulation
Solver Tab
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19 Refining Transitions
Petroleum Transition
HCR Product Transition
FCC Feed Adjust
Hydrocracker Feed Adjust
Reformer Transition
Index
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Contents
For the refinery reactor models, issues may occur when using a 32-bit machine.
You must enable the 3GB option in order to ensure that the refinery reactor models work correctly.
When defining component lists for HYSYSRefining, the default component lists
only contain pure components up to C5; C6 and above are hypothetical components. You can manually create pure components for C6 or C7, if desired. We
strongly recommend that you avoid overlapping between pure components and
hypothetical components. Overlapping between pure components and hypothetical components can cause issues due to calculations performed byHYSYSin
order to maintain consistency between hypothetical and pure components.
The Aspen HYSYS Petroleum Refining Reactor Models are a suite of rigorous
equation-oriented models within the Aspen HYSYS Petroleum Refining
functionality.Our suite contains all major refinery process units: Fluid Catalytic
Cracking, Naphtha Reforming, Hydroprocessing (Hydrocracking and Hydrotreating including Naphtha Hydrotreating), Delayed Coking, Visbreaking, and
Alkylation.The reactor models are designed to be calibrated to match plant
data and then used in simulation to predict results under various operating
conditions.Therefore, there are two major modes of operation: Calibration and
Simulation.In Calibration, plant data is fixed and model parameters move to fit
the plant data. In Simulation, the model parameters are fixed and then various
plant data is predicted.
To model the reactions involved in each process, HYSYSuses a set of "kinetic
lumps" to group molecules of a certain type together that undergo the same
type of reaction.To establish the composition of the kinetic lumps in the feed
stream, HYSYS uses the property information in the feed stream, the composition of the hypothetical and pure components in the feed stream, and in
some cases, a feed "fingerprint." The feed fingerprint is a representation of a
certain type of feed in terms of the kinetic lumps.The feed fingerprint is used
along with the data that you specified or data from the feed stream to properly
distribute the feed amongst the kinetic lumps used in the reactor model.
The reactor models also predict the properties of the product. These properties
are propagated throughout the rest of the flowsheet to supply the appropriate
information for downstream unit operations or product blending.
Calibration
For calibration runs, major reactor inputs and outputs are as follows:
Inputs
Outputs
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Simulation
For simulation runs, major reactor inputs and outputs are as follows:
Inputs
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Outputs
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Specifying reactor physical and dimensional data is optional, and you can use
rough estimates. In calibration, uncertainties in physical and dimensional data,
such as diameters, lengths, and catalyst inventories, are absorbed into the
apparent kinetic coefficients used to match plant yields. Accordingly, reactor
physical and dimensional data is not critical for model predictions.
Most product property data is optional. Some product properties, such as gravity and distillation, are deemed essential for determining yields. However,
other product properties are optional based on user priorities. For example, in
the FCC Reactor model, if RON and MON are not deemed important in simulation cases, then RON and MON input are not needed in calibration cases. In
other words, product property data in calibration runs is a required input if
accurate property predictions are needed in simulation runs for those properties.
The reactor models contain two types of adjustable, or "tuning," factors. First,
the models contain sets of kinetic coefficients that are called "kinetic" coefficients throughout this document. These coefficients are automatically calculated in a calibration run to force a match to reported plant conditions.
Secondly, the models contain other factors or advanced tuning constants that
can be adjusted to change model responses to move away from the calibration
case in simulation runs when the default responses resulting from the "kinetic
coefficients" are inaccurate.
Multi-flowsheet Architecture
The multi-flowsheet architecture of HYSYS Refining is vital to this overall modeling approach. Although HYSYS Refining has been designed to allow the use of
multiple property packages and the creation of pre-built templates, the
greatest advantage of using multiple flowsheets is that they provide an
extremely effective way to organize large processes. By breaking flowsheets
into smaller components, you can easily isolate any aspect for detailed analysis. Each of these sub-processes is part of the overall simulation, automatically calculating like any other operation.
HYSYS Refining uses a variety of methods to display process information - individual property views, the PFD, Workbook, graphical Performance Profiles, and
Tabular Summaries. Not only are all of these display types simultaneously available, but through the object-oriented design, every piece of displayed information is automatically updated whenever conditions change.
The inherent flexibility of HYSYS Refining allows for the use of third party
design options and custom-built unit operations. These can be linked to HYSYS
Refining through OLE Extensibility.
you provide three parameters, such as the efficiency, pressure rise, and work.
In the case of the Pump operation, there are three degrees of freedom, thus,
three parameters are required to fully define the outlet stream.
All information concerning a unit operation can be found on the tabs and pages
of its property view. Each tab in the property view contains pages which pertain
to a certain aspect of the operation, such as its stream connections or physical
parameters (for example, pressure drop and energy input).
Right-click any spot on an active plot and select the Graph Control command from the Object Inspect menu.
Click in the plot area to make the plot the active object. Then, either
double-click on the plot Title or Legend to access the respective tab of
the Graph Control property view.
The Tube Bundle option is only available for the following unit
operations: Separator, Three Phase Separator, Condenser, and
Reboiler.
Vessel Heater
Liquid Heater
If you select theVessel Heater radio button, 100% of the duty specified or calculated in the SPfield is applied to the vessels holdup.
Q = QTotal
(1)
where:
Q = total heat applied to the holdup
Q
Total
If you select the Liquid Heater radio button, the duty applied to the vessel
depends on the liquid level in the tank. You must specify the heater height in
Q=
(2)
(L < B)
Q=0
L B
Q
T B Total
Q = QTotal
(B L T )
(L > T )
where:
L = liquid percent level (%)
T = top of heater (%)
B = bottom of heater (%)
The Percent Heat Applied can be calculated as follows:
Q
QTotal
100 %
(3)
It is shown that the percent of heat applied to the vessels holdup directly varies with the surface area of liquid contacting the heater.
If you select the Direct Q radio button, the Direct Q group appears, and
you can directly specify the duty applied to the holdup in the SP field.
o
Object
Description
SP
Min.
Available
Max.
Available
If you select the Utility radio button, the Utility Properties group
appears, and you can specify the flow of the utility fluid.
o
The duty is then calculated using the local overall heat transfer
coefficient, the inlet fluid conditions, and the process conditions.
The calculated duty is then displayed in the SPfield or the Heat
Flowfield.
If you had an energy stream attached to the unit operation, HYSYS automatically
disconnects the energy stream when you switch to the Tube Bundle option.
The Tube Bundle option allows you to configure a shell tube heat exchanger
(for example, kettle reboiler or kettle chiller).
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In the kettle reboiler, the process fluid is typically on the shell side and
the process fluid is fed into a liquid "pool" which is heated by a number
of tubes. A weir limits the amount of liquid in the pool. The liquid overflow is placed under level control and provides the main liquid product.
The vapor is circulated back to the vessel.
In the kettle chiller, the process fluid is typically on the tube side with a
refrigerant on the shell side. The refrigerant if typically pure and cools
Description
Parameters group
Tube Volume
cell
Allows you to specify the volume of the tubes in the heat exchanger.
Vessel Liquid
U cell
Allows you to specify the heat transfer rate of the liquid in the shell.
Vessel Vapor
U cell
Allows you to specify the heat transfer rate of the vapor in the shell.
Tube Liquid U
cell
Allows you to specify the heat transfer rate of the liquid in the tube.
Tube Vapor U
cell
Allows you to specify the heat transfer rate of the vapor in the tube.
Heat Transfer
Area cell
Allows you to specify the total heat transfer area between the fluid in
the shell and the fluid in the tube.
Bundle Top
Height cell
Allows you to specify the location of the top tube/bundle based on the
height from the bottom of the shell.
Specs group
Tube Dp cell
Allows you to specify the pressure drop within the tubes. You have to
select the associate check box in order to specify the pressure drop.
Tube K cell
Allows you to specify the pressure flow relationship value within the
tubes. You have to select the associate check box in order to specify the
pressure flow relationship value.
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Object
Description
Tube UA
Reference
Flow cell
Allows you to set a reference point that uses HYSYS to calculate a more
realistic UA value. If no reference point is set then UA is fixed.
UA is the product of overall heat transfer multiply with overall heat
transfer area, and depends on the flow rate.
If a value is specified for the Reference Flow, the heat transfer coefficient is proportional to the (mass flow ratio)0.8 . The equation below
is used to determine the actual UA:
0.8
mass flowcurrent
UA actual = UAspecified
mass flowreference
Reference flows generally help to stabilize the system when you perform shut downs and startups.
Minimum
Flow Scale
Factor cell
The ratio of mass flow at time tto reference mass flow is also known as
flow scaled factor. The minimum flow scaled factor is the lowest value
which the ratio is anticipated at low flow regions. This value can be
expressed in a positive value or negative value.
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A negative minimum flow scale factor is often used in shut downs if you
are not interested in the results or run into problems shutting down
the heat exchanger.
If the Minimum Flow Scale Factor is specified, the actual UA is cal0.8 ratio if the ratio is greater than
culated using the
mass flowcurrent
mass flow
reference
the Min Flow Scale Factor. Otherwise the Min Flow Scale Factor is used.
Calculate K
button
Allows you to calculate the K value based on the heat exchanger specifications.
Shell Dp cell
Summary group
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Actual UA cell
Tube Liq.
Volume Percent cell
Shell Duty
cell
Object
Description
Use Tube
Trivial Level
and Fraction
Calc. radio
button
Allows you to select the volume percent level variable for the vessel
fraction calculation.
Use Tube
Normal Level
and Fraction
Calc. radio
button
Allows you to select the liquid percent level variable for the vessel fraction calculation.
View Tube
HoldUp button
This option uses a variable that is dependent on the vessel shape and
orientation.
Holdup Page
Each unit operation in HYSYS has the capacity to store material and energy. The
Holdup page contains information regarding the properties, composition, and
amount of the holdup.
Most Holdup page contains the following common objects/options:
Objects
Description
Phase
column
Displays the phase of the fluid available in the unit operations holdup
volume.
Each available phase occupies a volume space within the unit operation.
Accumulation
column
Displays the rate of change of material in the holdup for each phase.
Moles column
Volume
column
Total row
Displays the sum of the holdup accumulation rate, mole value, and
volume value.
Advanced but- Lets you access the unit operations HoldUp Property Viewthat
ton
provides more detailed information about the holdup of that unit operation.
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Nozzles Page
The Nozzles page (from the Rating Tab) in most of the operations property
view lets you specify the elevation and diameter of the nozzles connected to the
operation.
Note: The Nozzles page is only available if the HYSYS Dynamics license is activated.
Depending on the type of operation, the options on the Nozzles page vary. The
following table lists and describes the common options available in the page:
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Object
Description
Lets you specify the height/elevation between the bottom of the operation and the ground.
Diameter row
Stream Conditions
This page lets you define streams that are incomplete, or modify stream values
if you require changes in the simulation. Any blue colored value may be modified. This lets you easily define or modify a stream without opening the property view of each stream that is attached to the unit operation. This page also
lets you quickly see how the streams connected to the unit operation are acting
throughout the simulation.
Any changes made to this page are reflected in the streams property view. The
PF Specs page is relevant to dynamics cases only.
Stream Properties
This page lets you quickly see how the streams connected to the unit operation
are acting throughout the simulation. Any value that is blue in color indicates
that the value may be modified. Any changes made to this page are reflected in
the streams property view.
Stream Compositions
This page lets you define or modify the composition of streams attached to the
unit operation. Any value that is blue in color indicates that the value may be
modified. This lets you easily define or modify a streams composition without
opening the property view of each stream that is attached to the unit operation.
When you define or modify a composition, the Input Composition property view
property view appears. Any changes made to this page are reflected in the
streams property view.
PF Specs
PF (Pressure Flow) applies to dynamic simulations only.
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Note: The Heat of Vaporization for a stream in HYSYS is defined as the heat required for
the stream to go from saturated liquid to saturated vapor.
Equations Tab
Use the Equations tab to view and edit equations associated with the simulation.
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Case
Properties
Analysis
2. From the list above the Navigator Scope section, select the flowsheet/case/basis object/utility containing the variable(s) that you want.
The type of objects available in this list depends on your Navigator
Scope selection.
3. In the ObjectFilter section, either:
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Click Add to confirm the selection of the variable and keep the
Variable Navigator view open to select more variables. This button is only available when the operation allows multiple variable selection.
Click Cancel to close the Variable Navigator view without making any changes or variable selection.
Note: When a variable is selected in the Variable Navigator property view, a Disconnect button may appear. You can use the Disconnect button to remove/disconnect
the selected variable and close the property view.
The objects within the Select Type list are always limited to the types of
objects relevant to the current case or environment.
When you select an object in the Select Type view, only the selections
associated with that object are allowed into the parent selector.
Example
In the case of the Variable Navigator, for example, if you wanted to limit the
Variable Navigator Variables pane to show only variables associated with a certain mixer, you would use the Select Type dialog box to select the Mixer type of
object from the Piping Equipment selections. Your Variable Navigator "Object"
selections would then be limited to only the mixer or mixers in the case. You
would then make your variable selections from those objects.
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Object
Current Variable
Filter drop-down
list
Icon
Function
Lets you filter the list of variables in the table based on the
following types:
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All
Real
Enumeration
Text
Code Only
Message
Create a New
User Variable
icon
Lets you create a new user variable and access the Create
a New User Variable property view.
Lets you sort the user variable list in ascending alphabetical order.
Lets you sort the user variable list according to the order
by which they are executed by HYSYS.
You can also open the edit property view of a user variable
by double-clicking on its name in the table.
Sorting by execution order is important if your user variables have order dependencies in their macro code.
Normally, you should try and avoid these types of dependencies.
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Move Selected
Variable Up In
Execution Order
icon
Move Selected
Variable Down In
Execution Order
icon
Lets you move the selected user variable down in the execution order.
Operation
Compress Values
Set All
Allows you to set more than just the value and units when you
recall a case, if this is not checked you can only set values and units.
Force Setting
Attributes
Force the model to reset all of the attributes when you recall the
case
Opens the dialog box so that you can browse to the appropriate .var
file to save to or restore from
Current values
of OOMF Variables Save Assign
Save creates a separate internal array to store all of the EO variables. If selected, the other two boxes become active.
Update means the new array of EO variables gets updated when it
is run again
Assign means the current value for the EO variables are assigned
to this new array. It is recommended that if you select the save
option that you also select both update and assign.
Additionally, you can use the Save/Restore OOMF Variable Attributes dialog to manage variable attributes.
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Function
Operation
Save Restore
Check boxes
These are the attributes you want saved to the .var file that you are
saving to or restoring from.
Save Button
Restore Button
The attributes you want saved to the .var file that you are saving to or
restoring from
Restore Free
button
Same as the restore button, but that only calculated variables will be
restored and not specified variables.
File Type
Except Check
box
Solve Check
box
The model should solve after the .var file has been read in
One by One
check box
Clear List
List field
Enter which variables you want restored from the .var file (or which
ones you do not want restored, if you use the Except check box)
To enter notes:
1. Click anywhere in the Notes window to make it active.
2. Type in any relevant notes you have regarding such things as fluid packages, assays, user properties, operations, and so on.
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Notes Manager
The Notes Manager lets you survey and edit notes associated all objects on the
Flowsheet from a central location.
1. From the View ribbon tab | Show group, select Notes Manager.
2. In the list of available objects, select the object that contains the note
you want to view. Click the Plus icon to expand the tree browser revealing more selections.
3. If a valid note is present in the object, the note appears in the Note
group. From here, you can view and modify the note.
Tip:You can also access the Notes Manager by pressing the CTRL G hot key.
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Select the View Objects with Notes Only check box to display only
objects that contain a valid note.
Click Clear to delete the entire note from the selected object.
Select the Search notes containing the string check box and enter a
string in the corresponding field to filter the list of available objects to
objects that contain the specified string.
Select the Search notes modified since check box and enter month,
day and year to filter the list of available objects to objects whose notes
modified since the specified date.
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24
3 Petroleum Distillation
Column
The Petroleum Distillation Column operation lets you model petroleum distillation columns in a refinery. The Petroleum Column is specifically designed to
help with solving the following problems:
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Note: If you require significant internal details of the column such as vapor-liquid traffic or
temperature profiles matching very closely to plant data, or if you are interested in
extreme flexibility in the specifications or the topology of the column, you should use the
standard HYSYS column subflowsheet.
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Description
Tower
A HYSYS unit operation that represents the series of equilibrium trays in a Column.
Column Sections
Overhead Vapor
Product
Overhead Liquid
Product
Overhead Condenser
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Notes:
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When the Column is solving, the Run and Reset buttons are replaced by a Stop
button that, when clicked, terminates the convergence procedure. The Run button can then be clicked again to continue from the same location.
Click the Reset button to clear the current petroleum distillation column solution
and any estimates. If you make major changes after getting a converged petroleum distillation column, it is a good idea to reset the column to clear the previous solution. This allows the petroleum distillation column solver to start fresh. If
you make only minor changes to the column, try clicking the Run button before
resetting.
Consider a simple distillation column with one feed and two products only. For
near ideal systems such as hydrocarbon systems, it is possible to correlate the
distillate and bottoms flow as shown in the figure below:
If one plots the quantity ln(Di /Bi ) vs. NBPi for each component i, the plot is typically bi-linear.
Di = molar component flow of component i in the distillate
Bi = molar component flow of component flow of component i in the bottoms
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ln
=
NBPi + KD , N if d i > b i for all i
D, N
N ,i
=
NBPi + KB , N
if d i < b i for all i
B, N
f N , i = dN , i + bN , i
for all i
(1)
(2)
DN = dN , i
(3)
BN = bN , i
(4)
FN = DN + BN
(5)
(6)
Where:
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Note: You are required to specify fractionation indices for each section, pressure for each
section, and product flow fractions for each product coming out of the column including
the condenser.
The sections are numbered from bottom of the column to the top of the column.
The above system of equations is then solved for dN,i , bN,i , fN,i , KD,N, and KB,N.
Water Handling
The above equations assume a water-free basis. As a result, the quantity of
water calculated through the equations is zero. Water from the feed and stripping steam is allocated to the water draw stream.
Condenser Handling
The equations in the preceding Theory section generate the composition of each
product stream coming out of the petroleum column. It is assumed that each
liquid product of the petroleum column is at its bubble temperature and each
vapor product is at its dew temperature. With this assumption and a specified
pressure, you can flash a product stream and calculate its temperature.
Condenser duty is calculated such that energy balance around the petroleum
column is satisfied:
Condenser Duty = Energy Out - Energy In = Product Enthalpies - Feed Enthalpies - Reboiler Duties
In the above case, the intention is to inform the column to split the crude oil
into five product streams.
The five product streams will have the following qualities:
29
top product is cut from the initial boiling point of the crude up to 100 C
residue product is cut from 320 C to the final boiling point of the crude
These cut points are translated into molar flow fractions of the feed.
In a crude column, there are no degrees of freedom to exactly achieve the specified cut points at both ends of the column. Furthermore, the column achieves
perfect separation only at an infinite number of stages.
Aspen HYSYS Refining can model imperfect separation and therefore achieve
the separation as shown in the figure below:
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icon.
4. Use the first-time setup view to select the feed stream, enter a total
number of stages and specify the feed stream stage. It is recommended
to specify a sufficient No. of Stages. The default is 10.
5. Click OK. You can now use the Petroleum Column Property View Specs
page to configure the column.
Specs Page
The Specs page on the Design tab configures the petroleum column.
The following table lists and describes the common objects at the Petroleum
Column Specs page.
Object
Description
Column
Name
Specification
Type
Basis
Separate
Pure Component
Product Cut
check box
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Object
Description
Product Info
Matrix
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Feed Info
Add Product
Remove
Product
Import SCD
Save SCD
Run
Reset
Object
Description
Stop
Stop the column calculation before column convergence. The button is only available when the
column convergence is in progress.
Status
Ignore
Toggle between ignoring or considering the petroleum column during process flowsheet calculations.
AdvancedPage
The Advanced page on the Design tab configures the advanced options in a
petroleum column, such as pressure and reboiler duty.
In the Zone Info section:
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The Zone Start and Zone End columns display which Towers mark the
start and end of each zone. You can edit the zone end values using the
Draw Stage column on the Design | Specs page.
In the Zone Top Pressure column, you can edit the top pressure for
the zone.
The Reboiler Duty column displays the reboiler duty for each zone.
The Steam Flow column displays the steam flow rate for each zone.
In the Bottoms section, you can specify the pressure and heat duty for the bottoms reboiler.
Performance Tab
Use the Petroleum Column Performance tab to set up the Summary, Energy
Balance and Plot attributes of the column.
Summary
The Summary page gives a tabular summary of the feed or product stream
properties. Select the appropriate radio button to display the information you
want to see.
Energy Balance
The Energy Balance page displays the energy flow of any Reboilers and condenser within the Petroleum Column. The table displays the following data for
each energy stream entering and exiting the column: name, unit operation connected to the stream, duty (the direction of the energy stream is indicated by
the sign of the duty), and type (whether it is a heater or cooler).
33
Plots
The volume interchange plot displays two types of information: Cumulative
and Incremental. You can toggle between Cumulative and Incremental by
selecting the appropriate radio button in the Volume Interchange group.
34
Worksheet Tab
The Worksheet tab presents a summary of the information held by the stream
or operation object. The Worksheet tab on each unit operation provides access
to the streams attached to the unit.
Worksheet pages contain analytical information on the Worksheet and/or Performance tabs. The type of analytical information found in operation property
views depends on the operation type. Regardless of what the operation is, the
displayed information is automatically updated as conditions change.
For Streams, you can use the Worksheet tab Composition page to define a
material stream. The Worksheet tab Properties page contains detailed property
correlation information. The Conditions page is a subset of the information
provided in the Properties page.
The following pages are common to all worksheet tabs:
Conditions
Displays conditions for all streams attached to a unit operation. Lets you define
streams that are incomplete, or modify stream values if you require changes in
the simulation. You can modify any blue value. This lets you easily define or
modify a stream or streams without opening the individual property view of
each one. Any changes made in this page are passed to the edited streams own
property view.
Properties
Subset of the Conditions page. This page lets you quickly see how the streams
connected a unit operation are acting throughout the simulation. You can
modify any blue value. Any changes made to this page are passed to the edited
streams own property view.
Composition
This page lets you define or modify the composition of streams attached to a
unit operation. You can modify any blue value. When you define or modify a
composition, the Input Composition property view property view appears.
Any changes made to this page are reflected in the streams property view.
Calibration Tab
The Calibration option in the petroleum column lets you calculate the parameters (fractionation indices) of the section-by-section model. The calculated
parameter values can be use to configure the column in the simulation case.
The required input values of the calibration option are:
l
Feed temperature
35
Plots page:
l
Slope results
Feed curve
Feeds Page
The Feeds page lets you to calibrate the feed stream entering the Petroleum
Column.
The following table lists and describes the objects available in the Feeds page:
36
Object
Description
Number of Zones
Products Page
Use the Products page to enter the product flows, properties and distillation
information necessary for petroleum column calibration.
The following table lists and describes the objects available in the Products
page:
Object
Description
Product Enumeration
Distillation Curve
cell
No of Points to
Add
Distillation Basis
Radio button
Yield Matrix
Temperature Matrix
Component
Name Matrix
NBP Matrix
Clear Product
Data Button
Clear Empty
Points Button
If you select Short Cut Column, data is generated when you press OK.
If you choose Rigorous Column, you are prompted to map streams
from the selected petroleum column to a selected rigorous column
37
Tables Page
The Tables page allows you to see the calibrated parameters and calibrated
feed composition. This page also allows user to select which algorithm to
choose for calibration.
The following table lists and describes the objects available in the Tables page.
38
Object
Description
Tuning Parameters
Table
Feed Composition
Table
Calibration
Algorithm
Radio button
Initialization
Button
Active if the Advanced Initialization check box is selected on the Calibration Parameters View. Opens the Calibration Initialization View
buttons and table.
Parameters
Button
Active only if Rigorous Optimization radio button is selected. Opens Calibration Parameters View for rigorous optimization parameters.
Results Button
Active only if Rigorous Optimization radio button is selected. Opens a window to view the calculated and supplied TBP distillation curves.
Calibrate
Button
Start calibration
Transfer
Tuning Parameters Button
Description
Convergence
Tolerance
Set Creep Step Parameters On or Off, Set iterations and step size.
Failure
Recovery
Action
Do Nothing
Advanced Ini- If the Advanced Initialization check box is selected, the initial values
tialization
are pulled from the Calibration Parameter Initialization View
check box
table (accessed by selecting Calibration | Table | Initialization |
View Initial Values). If the check box is cleared, then the calibration
uses the initial values calculated from the SCD algorithm.
Description
View Initial
Values
Shows current initial values and bounds for ECP, SI TOP, SI BOTTOM
and ECP Offset
39
Object
Description
Saves initial values for calibration as updated from the last converged
solution.
Initialize
From Seq.
Calibration
Initial values for ECP, SI TOP, SI BOTTOM and ECP Offset are generated
from sequential (short-cut) calibration method.
Initialize
Default
ECP values are initialized from sequential calibration, ECP Offset is initialized as 0.0 and SI TOP and SI BOTTOM are initialized using default
program value.
Plots Page
The Plots page displays the calculated calibration results in plot format. From
the drop-down list, select the product stream zone you want to view in the plot.
40
4 Petroleum Feeder
The Petroleum Feeder allows flexibility over how the crude proportions are
defined and allows you to mix petroleum assays from the Oil Environment with
assays from other streams in the flowsheet.
In addition, you can setup feeds as blends and/or cuts of petroleum assays.
Streams can also be setup to represent spiked or partial crudes.
Note: You must specify the temperature, pressure, and flow rate of the product stream
exiting the Petroleum Feeder. You can specify these values in the Worksheet tab or the
product streams property view.
. The Petroleum
Tip: Click the Ignored check box to tell HYSYS ignore the unit operation when
solving the simulation.
4 Petroleum Feeder
41
42
4 Petroleum Feeder
Description
Ratio
You can specify the flow ratio of the petroleum assay(s) and stream
assay(s) that makes up the petroleum feeder product stream.
For example, if you selected Mole as the unit basis of the flow ratio,
and you specify the Arab assay to have a ratio of 0.25, then 25% of
the product stream's mole composition is from the Arab assay.
The sum values under the Ratio column must equal 1.
4 Petroleum Feeder
43
Column
Description
IBP
You can specify a different initial boiling point temperature for the Petroleum Feeder blending calculation.
You cannot specify values lower than the HYSYS default temperature.
The default values of the IBP and FBP are the boiling temperature of
the lightest and heaviest components in the component list, respectively. These values are derived from the property values for the components used by the assay. These are not the initial and final points of
the TBP curve of the assay.
FBP
You can specify a different final boiling point temperature for the Petroleum Feeder blending calculation.
You cannot specify values higher than the HYSYS default temperature.
Tips:
l
You can narrow the boiling point range considered from the assays and streams by,
typing the initial and final boiling point temperature in the appropriate cell(s) under
the IBP and FBP columns.
To return the IBP and FBP to their default values, select the appropriate cell and
press DELETE. HYSYS automatically replaces the previous value with the default
value.
44
4 Petroleum Feeder
Note: You must specify the temperature, pressure, and flow rate of the product stream
exiting the Petroleum Feeder. You can specify these values in the Worksheet tab |
Conditions page or in the product streams property view.
4 Petroleum Feeder
45
46
4 Petroleum Feeder
5 Product Blender
The Product Blender allows you to mix several streams together, and calculate
a blended property value or optimize the properties in the product stream by
back calculation and determine the optimum mix ratios for the inlet streams.
This unit operation is like a "black box" consisting of splitters and mixers. Each
inlet stream enters a Tee or splitter, which splits the stream based on the specified flow ratio. Then the split streams enter the appropriate mixer. Each
mixer represents the blended product stream. The Product Blender also has a
surplus stream that is used to maintain mass balance in the unit operation system.
For example, consider the above figure of a blender with three inlet streams,
two product streams, and one surplus stream. Product streams E and D are a
mixture of inlet streams C, B, and A as indicated by the colored lines. The surplus stream provides an exit flow for left over fluid from the inlet streams, as
shown in the above figure for inlet streams A, C, and B.
5 Product Blender
47
48
5 Product Blender
and objective function scaling, a basic watchdog method, and a problem-independent and scale-independent relative convergence test. The algorithm also
ensures that the model is evaluated only at points feasible with respect to the
variable bounds.
The cutter is added to reduce the calculation time required during the PFD calculation process. If all the operations and streams in the PFD need to be recalculated every time the optimizer generates a possible solution, then the entire
calculation would take too long or lose required information for the entire PFD
to solve. So HYSYS places a cutter that will temporary separate the Product
Blender from the rest of the PFD during the optimization calculation. When the
optimum value is found, the value is propagated back into the PFD.
The stream cutter is also inactive only during the optimization calculation process in the Product Blender. Before and after the calculation process, the
stream cutter is active and allows information from the Product Blender's output streams to flow to the rest of the process flowsheet diagram.
5 Product Blender
49
Note: The stream cutter is only placed when there is an operation downstream to the
Product Blender (in other words, an operation connected to the outlet streams of the
Product Blender).
There are four common objects at the bottom of the Product Blender property
view; the following table describes these objects:
Object
Description
Status bar
Displays the current status of the operation (for example, missing information or errors encountered during calculation).
Delete button
Calculation
Mode dropdown list
Ignored
check box
5 Product Blender
Select the Variables-Config page and configure the opt. variables that will be manipulated/optimized during the optimization calculation.
Select the Variables-Inputs page and specify the range of values the opt. variables will consider during the optimization calculation.
Select the Constraints-Config page and configure the constraints in the optimization calculation.
5 Product Blender
51
The Simulation model which treats the Product Blender as a black box
splitter-mixer.
For the Simulation model, you are required to specify the stream connections and flow ratios. The Simulation option must also be selected in
the Calculation Mode drop-down list.
The Optimization model which determines the optimum mix ratio of inlet
streams to obtained the specified objective values in the product stream
(s).
For the Optimization model, you are required to specify the stream connections, optimization variables, process constraints, objectives functions, and optimizer solver parameters. The Optimization option must
also be selected in the Calculation Mode drop-down list.
The reason for the cutter is to reduce the calculation time required during the
PFD calculation process. If all the operations and streams in the PFD need to be
recalculated every time the optimizer generates a possible solution, then the
entire calculation would take too long or lose required information for the entire
PFD to solve. So HYSYS place a cutter that will temporary separate the Product
Blender from the rest of the PFD during the optimization calculation. When the
optimum value is found, the value is propagated back into the PFD.
52
5 Product Blender
Note:The stream cutter is only placed when there is an operation downstream to the
Product Blender (in other words, an operation connected to the outlet streams of the
Product Blender).
Specifying Parameters
The Product Blender Parameters tab contains the Parameters page. This
page lets you specify the inlet streams split ratio among the product streams,
and select the type of automatic pressure assignment option.
1. Select the Parameters tab for the Product Blender.
2. In the Flow Ratios group, specify the flow ratio of the inlet streams
going into the product streams.
For example, consider a blender consisting of two inlet streams (A and
B), one outlet stream (C), and one surplus stream. If stream C is a mixture of 27% stream A and 100% stream B, then the table in the Flow
Ratios group will appear as shown below:
5 Product Blender
53
The values in the rows of the Flow Ratio table represent split ratios of
the inlet streams, so the sum of values along each row must equal 1.
Note:HYSYS automatically calculates the left over flow ratio value for the surplus
stream.
3. In the Automatic Pressure Assignment group, select one of the following options to determine the product blender pressure:
o
Equalize All: HYSYS gives all attached streams the same pressure.
Note:If you are uncertain of which pressure assignment to use, select the Set Outlet to
Lowest Inlet option. Only select the Equalize All option if you are completely sure that
all the attached streams should have the same pressure.
54
Page
Function
Variables |
Config
Modify initial values of the optimization variables used in the optimization calculation. The optimization variables are variables that will
be modified to achieve the specified goal in the optimization calculation.
Variables |
Inputs
Variables |
Results
Constraints |
Config
5 Product Blender
Page
Function
Constraints |
Inputs
Constraints |
Results
Displays the calculated results of the constraints from the optimization calculation. If the Calculation Mode is not set to Optimization and the optimization calculation has not been performed,
the Results pages will contain empty results.
Objectives
Optimizer |
Configuration
Optimizer |
Results
The following table describes the common objects at the bottom of the Optimization tab:
Object
Description
The flow ratios between the inlet and product streams for
the optimization variables.
The flow ratios between the inlet and surplus streams for
the process constraints.
View Derivative
Utility
Create Optimizer
View Optimizer
Add
5 Product Blender
55
Object
Description
Types of Parameters
Opt Variable
Constraint
Objective
56
5 Product Blender
Description
Opt Variable
Hooked
Object
Hooked
Property
Current
Value
Use
Allows you to toggle between using or ignoring the optimization variable during optimization calculation.
check
box
You can access the Optimization Object Property View of the variable by
double-clicking on the variable name.
A selected check box indicates the variable is being used in the calculation.
5 Product Blender
57
Column
Description
Minimum
Allows you to specify the lower bound property for the variable during the
optimization process.
This value might be different from its global minimum, if the change in the
variable is restricted to its allowed amount, set by the maximum rate of
change, during the period in the optimization process.
Current
Value
Allows you to specify the current variable value before optimization calculation.
Maximum
Allows you to specify the upper bound property for the variable during the
optimization process.
This value might be different from its global maximum, if the change in
the variable is restricted to its allowed amount, set by the maximum rate
of change, during the period in the optimization process.
Range
Global
Min.
Allows you to specify the absolute minimum value for which the variable is
operated.
Global
Max.
Allows you to specify the absolute maximum value for which the variable
is operated.
58
Column
Description
Start
Value
Current
Value
Allows you to specify the current variable value before optimization calculation.
5 Product Blender
Status
Displays the current status of the variable, which is calculated by the Optimizer. Unlike constraints, opt. variables are not allowed to move out of their
bounds. The Status property is set to one of:
l
Equality: Maximum and minimum properties of the variable, Minimum and Maximum, are equal, and the Output property has the
same value as well.
Active Low: Variable Output property value is equal to that of the Minimum.
Price
Displays the shadow price (Lagrange multiplier) for the given opt. variable,
calculated by the Optimizer. The shadow price is used to estimate the effect
which small changes to variable bounds have on the plant cost function.
Span
Displays the difference between the Global Minimum and Global Maximum
values for the variable and is calculated by the variable set-up.
The role of the span is to convert every variable into the range (0, 1), to use
uniform numerical perturbations and convergence tests.
Output
Displays the current value of the variable in the plant model. The output
value is determined by the optimizer during the optimization process.
Description
Constraints
Hooked
Object
Hooked
Property
5 Product Blender
59
Current
Value
Use
check box
A selected check box indicates the constraint is being used in the calculation.
Description
Minimum
Current
Value
Maximum
Scale
Allows you to specify the number scale on which the feasibility of the constraint is measured. This property is used in conjunction with the Optimizer Zeta property, which is a relative feasibility tolerance.
In general, a constraint is said to be feasible if:
Minimum Scale Zeta < Current < Maximum + Scale Zeta
where:
Minimum = lower bound properties of the constraint
Maximum = upper bound properties of the constraint
Current = current constraint value (equivalent to Hooked Property for
constraints, which have the Use check box selected)
Min.
Chi^2
60
5 Product Blender
Column
Description
Current Value
Status
Normalization
5 Product Blender
Not Evaluated: The status of the constraint has not been evaluated by the Optimizer.
Inactive: The constraint current property lies between the Minimum and Maximum properties, but is neither Active High nor
Active Low
Violated Low: The constraint current property is less than Minimum - Scale x Zeta, where Scale is the constraint Scale property and Zeta is the Optimizer Zeta tolerance property.
Active Low: The constraint current property is less than Minimum + Scale x Zeta, but greater than Minimum - Scale x Zeta.
Active High: Constraint current property is greater than Maximum - Scale x Zeta, but less than Maximum + Scale x Zeta.
When the Jacobian matrix is first calculated (first pass evaluation) the
Normalization property for the constraint is set to be the largest
Jacobian entry in the row (Sparse Row) of the Jacobian matrix corresponding to this constraint. This number is used to normalize the
rest of the given Jacobian row, for all remaining Optimizer search steps
(in other words, it is not recalculated).
61
Base Value
Price
Displays the shadow price (Lagrange multiplier) for the given constraint, calculated by the Optimizer.
If a feasible solution is found by the Optimizer, then a simple interpretation of the Lagrange multiplier is that it gives the gradient of the
cost function along the corresponding constraint normal. Thus, the
shadow price indicates the approximate change to the objective function when increasing (in other words, relaxing) the given active bound
by a unit amount.
Objectives Page
The Objectives page allows you to specify the name and price of the objectives. The objectives are the goals you specified for the optimization calculation.
To access the Objectives page, select Objectives branch from the tree
browser.
The table in the Objectives page contains the following information:
Column
Description
Objective
Hooked
Object
62
5 Product Blender
Hooked
Prop
Current
Value
Weighted
Value
Displays the difference between the previous objective value and the new
optimized objective value.
Price
Allows you to specify the price value. The objective function value is calculated using the following equation and price value:
Objective Function Value = Price Value Current Value
For minimum objective value, price value = 1. For maximum objective
value, price value = -1.
To remove an objective, select the objective under the Objective column and
press DELETE.
Description
Maximum
Iteration
field
Objective
Scaling
Factor field
Allows you to scale the objective function. Positive values are used as-is,
negative values use the factor abs(scale*F) (where F is the initial objective function value) and a value of 0.0 a factor is generated automatically.
Gradient
Calculation
Method
dropdown list
Specifies what type of differences are being used when constructing gradient approximations. 1-sided causes forward differences to be used. 2sided causes central differences to be used.
5 Product Blender
63
Diagnostic
Print Level
drop-down
list
Accuracy
Tolerance
field
A relative accuracy tolerance used in the test for convergence. The following convergence test is used:
M
r
ConvergenceSum = F (x) d +
()
u jC j x
j =1
The ConvergenceSum is a weighted sum of possible objective function
improvement and constraint violations, and has the same units as the
objective function. This allows the same tolerance parameter to be used
for different problems, and makes the convergence test independent of
objective function scaling.
Step
Restriction
field
A line search step-size restriction factor used during the first 3 iterations.
Values greater than 1.0 result in no step restriction. Set the factor to 1.0,
-1
-2
10 , 10 , etc. to impose larger restrictions.
Perturbation
Size field
Maximum
Feasible
Points field
Description
Starting
Objective
Value
64
5 Product Blender
Termination
Reason
Displays the termination status of the Optimizer. Values include Running, Step convergence, Unbounded, Impossible, Not run, and Stopped.
Feasible
Point Iterations
Displays the number of minor iterations since the last major iteration.
Solution
Phase
Displays the current phase of the Optimizer algorithm. Values include Initialize, Setup, OPT Deriv, OPT Search, and Results.
Gradient
Evaluations
Actual
Optimizer
Model
Evaluations
Code Version
Total CPU
Time
l
l
5 Product Blender
65
66
Click the View Derivative Utility button to access the detailed Derivative Utility view.
Click the View Optimizer button to access the detailed Optimizer property view.
Double-click the name of the opt. variable or constraint to open the Optimization
Object property view.
5 Product Blender
Notes:
l
After clicking the Create Derivative Util and Create Optimizer buttons, they
are replaced with View Derivative Utility and View Optimizer buttons.
2. Click the Add button. The Select optimization variables property view
appears.
3. Under the Flowsheet list, select the flowsheet that contains the optimization variable.
4. From the Object Filter group select the radio button you want to use to filter the object list. For example, clicking the Streams radio button will
show only streams in the object list.
5. From the Object list, select the object whose variable you want to use.
6. From the Variable list, select the variable you want to use.
7. Certain variables (such as component specific variables) require further
specification. From the Variable Specifics list, select the qualifier for the
variable.
8. Enter a more detailed description of the variable in the Variable
Description field or leave the HYSYS default description.
5 Product Blender
67
9. Click OK to accept the variable. The Select optimization variables property view will close and you return to the Optimization tab.
68
5 Product Blender
6 Catalytic Reformer
6 Catalytic Reformer
69
Calibration Environment
ConfigurationOptions
Configuration Options
#
Beds
Type
Recontactor
3-6
CCR or SemiRegen
Yes or No
Simulation
Major Simulation Inputs
l
70
Configuration data, such as like number of reactor beds, the reaction bed
path lengths, and catalyst inventory of each bed
6 Catalytic Reformer
Recycle gas rate to first reactor bed and to other beds (if present)
Catalyst Rate for CCR as well as coke on catalyst for last reactor
Coke on catalyst at start of time period, start time, and end time for
semi-regen configuration
Recontactor drum Temperatures and Pressures for systems with recontactors
Kinetic coefficients as determined from a calibration run:
o
6 Catalytic Reformer
IC4 Isomerization
IC5 Isomerization
C5 Cyclization
C6 Multi-branch isomerization
C7 Multi-branch isomerization
C8 Multi-branch isomerization
C6 Single-branch isomerization
C7 Single-branch isomerization
C8 Single-branch isomerization
C1
C2
C3
C4
Dehydrogenation
Hydrocracking
71
Multi-branch isomerization
Single-branch isomerization
Ring closure
Ring expansion
C7 Naphthenics
C8 Naphthenics
C5
C6
C7
C8
C9
C10
C5
C6
C7
C8
C9
C10
C11
C6 Multi-branch isomerization
C7 Multi-branch isomerization
C6 Single-branch isomerization
C7 Single-branch isomerization
C6
C7
C8
72
DP Factors
o
Reactor 2 Heater
Reactor 3 Heater
Product Separator
6 Catalytic Reformer
Compressor Discharge
Compressor Suction
Reactor 1
Reactor 2
Reactor 3
Global Activity
o
Reactor 1
Reactor 2
Reactor 3
Pinning Coefficients
o
Reactor 1
Reactor 2
Reactor 3
C5+ RON
C6+ RON
C5+ MON
C6+ MON
Product Separator
Murphree Efficiency
WAIT, WABT, Aromatics Percent of Feed, and product RON and MON
Calibration
Calibration requires all of the same inputs as simulation, except for the kinetic,
property, and miscellaneous coefficients highlighted above.These are calculated by the calibration case.In order to calculate these coefficients and
factors, the calibration requires some product data.
6 Catalytic Reformer
73
Calibration Options
l
74
6 Catalytic Reformer
Description
H2
Hydrogen
P1
Methane
P2
Ethane
P3
Propane
P4
Butanes
P5
Pentanes
5N5
Cyclopentane
MBP6
Mult_Branched_P6
6 Catalytic Reformer
75
76
SBP6
Sing_Branched_P6
NP6
Normal_P6
5N6
5_Napthene6
A6
C6_aromatics
6N6
6_Napthene6
MBP7
Mult_Branched_P7
SBP7
Sing_Branched_P7
NP7
Normal_P7
5N7
5_Napthene7
A7
C7_aromatics
6N7
6_Napthene7
MBP8
Mult_Branched_P8
SBP8
Sing_Branched_P8
NP8
Normal_P8
5N8
5_Napthene8
A8
C8_aromatics
6N8
6_Napthene8
IP9
Isoparafin9
NP9
Normal_P9
5N9
5_Napthene9
A9
C9_aromatics
6N9
6_Napthene9
IP10
Isoparafin10
NP10
Normal_P10
5N10
5_Napthene10
A10
C10_aromatics
6N10
6_Napthene10
IP11
Isoparafin11
NP11
Normal_P11
5N11
5_Napthene11
A11
C11_aromatics
6 Catalytic Reformer
6N11
6_Napthene11
P12
C12_Paraffin
N12
C12_Naphthene
A12
C12_Aromatics
P13
C13_Paraffin
N13
C13_Naphthene
A13
C13_Aromatics
P14
C14_Paraffin
N14
C14_Naphthene
A14
C14_Aromatics
Coke
Coke
6 Catalytic Reformer
77
Cyclopentane
24-Mpentane
O8*
6N9*
N12*
Methane
22-Mbutane
2-Mhexane
n-Octane
IP10*
A12*
Ethane
23-Mbutane
3-Mhexane
5N8*
n-Decane
P13*
Ethylene
2-Mpentane
3-Epentane
E-Benzene
5N10*
N13*
Propane
3-Mpentane
n-Heptane
o-Xylene
A10*
A13*
Propene
n-Hexane
O7*
m-Xylene
6N10*
P14*
i-Butane
O6*
11Mcycpentan
p-Xylene
IP11*
N14*
n-Butane
Mcyclopentan
Ecyclopentan
6N8*
n-C11
A14*
1-Butene
Benzene
Toluene
IP9*
5N11*
i-Pentane
Cyclohexane
Mcyclohexane
n-Nonane
A11*
n-Pentane
22-Mpentane
MBP8*
5N9*
6N11*
O5*
23-Mpentane
SBP8*
A9*
P12*
O: Olefin
A: Aromatic
These components are either used directly in the kinetic reactor model or they
are easily mapped into the components used within the kinetic reactor model.
The transition between the Main Environment and the Catalytic Reformer Environment will handle the calculation of the composition of the Reformer components. In order to do this, however, you must specify the feed type. The feed
type will specify the ratios of various isomers within the feed to the Reformer.
These ratios, along with the distillation and PONA data from the attached inlet
stream will be used to calculate the Reformer component compositions.
78
6 Catalytic Reformer
MB P6 / Total P6 Ratio
MB P8 / Total P8 Ratio
MB P7 / Total P7 Ratio
In the Catalytic Reformer Environment, you have more options for calculating
the composition of the feed. The you can calculate the composition based on a
boiling range of an assay, based on the specified bulk properties, or based on
the specified the kinetic lumps.
l
For the assay option, you select an assay to associate with the feed. The
feed type is specified along with the initial and final boiling point to generate a composition of the feed.
For the bulk properties option, you specify the feed type along with distillation data and total naphthenics and aromatics in the feed.
6 Catalytic Reformer
79
You can specify as many feeds as desired to be fed into the reactor section. You
can connect external feeds with necessary feed properties (PONA and distillations) or specify internal feeds. For internal feeds, you can specify feed
properties (PONA and distillation), point to an assay with the necessary feed
properties, or specify the composition on a component by component basis.
Only a subset of the overall components are used within the reactor section, so
you can specify the composition using either GC Recommend, where only the
components used in the reactor section are specified, or GC Full, where all
components will be specified.
The reactor/heaters are hierarchy blocks consisting of several models to handle
the reaction kinetics, catalyst deactivation, unit operation calculations and
heater modeling.
The feed effluent exchanger is modeled as a simple hot side approach
exchanger, which closely replicates the performance of both the vertical and
plate exchangers in common use.
80
H2
NP6
O8
IP11
P1
5N6
5N8
NP11
P2
A6
A8
A11
6 Catalytic Reformer
O2
6N6
6N8
A11
P3
MBP7
IP9
6N11
O3
SBP7
NP9
P12
P4
NP7
5N9
N12
O4
O7
A9
A12
P5
5N7
6N9
P13
O5
A7
IP10
N13
5N5
6N7
NP10
A13
MBP6
MBP8
5N10
P14
SBP6
SBP8
A10
N14
O6
NP8
6N10
A14
The component names can be interpreted by identifying the prefix with the component type and the suffix with the carbon number. The prefix component types
are:
l
O: Olefin
A: Aromatic
The components P4, P5, and A8 are further delumped after the reaction network. P4 and P5 are mapped into their corresponding normal and isoparaffin
components. A8 is mapped into ethylbenzene, o-xylene, m-xylene, and pxylene.
Reaction Paths
Nine fundamental reaction types are used in reformer kinetics:
ReactionType
6 Catalytic Reformer
Example
81
Isomerization
NP6 SBP6
Ring Close/Open
NP6 5N6
Ring Expansion
5N6 6N6
Dehydrogenation
6N6 A6 + 3H2
Hydrogenolysis
6N7 + H2 6N6 + P1
Hydrocracking
P5+ H2 P2 + P3
Hydrodealkylation
A7 + H2 A6 + P1
Polymerization
A7 + P5 A 12 + H2
Condensation
The reaction paths used for C6 through C8 are shown in the following diagram.
As the carbon number increases beyond 8, the complexity of the paths is
reduced.
Where:
x: carbon number from 6 to 8
nP: normal paraffins
SP: single-branch paraffins
MP: multi-branch paraffins
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6 Catalytic Reformer
Where:
Activity = product of catalyst activity, metal site activity, and dehydrogenation
specific activity
k = Arrhenius form of the forward reaction rate multiplier
f
eq
PFx
Application
Isomerization
Ring Close/Open
6 Catalytic Reformer
83
Reaction Type
Application
Ring Expansion
Dehydrogenation
Hydrogenolysis
Hydrocracking/Hydrodealkylation
Polymerization
Paraffin Coking
Naphthene Coking
Aromatic Coking
10
Examples
Isomerization
NP6 SBP6
Ring Close/Open
NP6 MCP
Ring Expansion
MCP CH
Dehydrogenation
CH A6
Hydrogenolysis
Hydrocracking
Hydrodealkylation
A7 + H2 => A6 + CH4
Polymerization
A7 + C5 => A12 + H2
Paraffin Coking
Polymerization
Polymerization
A7 => COKE + H2
84
REACT_A
REACT_B
REACT_C
6 Catalytic Reformer
REACT_A
REACT_B
REACT_C
Then, during the subsequent cases, the catalyst activity is adjusted to match
the user-defined coke on catalyst using model CATACT.
The interaction is shown below.
A Feed/Reactor section.
A Separator section.
6 Catalytic Reformer
85
For C6 through C8, the paraffins are divided into three types
normal, single branched iso-paraffin (SBP) and a multi-branched
iso-paraffin (MBP). From C9 through C11, the iso-paraffins are all
represented by a single lumped iso-paraffin. The C12 through
C14 paraffins are all lumped as a single paraffin.
Olefins
Naphthenes
Aromatics
Type
Feed
Product
28
Olefins
None
Paraffin
Lump P4
Paraffin
Lump P5
Aromatic
Lump A8
86
Reactor Section
Heaters
Stabilizer
Reformate Properties
6 Catalytic Reformer
Reactor Section
l
WAIT
WABT
LHSV
WHSV
Pinning
Heaters
l
Absorbed duties
Fired duties
Tubeskin temperatures
Stabilizer
l
Condenser Duty
Reboiler Duty
IC4
NC4
IC5
NC5
NC6
Benzene
Reformate Properties
l
C5+ RON
C5+ MON
C6+ RON
C6+ MON
RVP
6 Catalytic Reformer
87
the following pressure drops based upon the base case pressure drops and flowing conditions and the users specified flowing conditions:
l
Acid
Isomerization
Ring Closure/Open
Ring Expansion
Metal
Pressure
Multiplier
Dehydrogenation
Hydrogenolysis - Para
Hydrogenolysis - Naph
Hydrocracking/Hydrodealkylation
Polymerization
Paraffin Coking
Naphthene Coking
Aromatic Coking
The acid and metals activities are independent functions of carbon on catalyst
expressed as percent. The general form for both the acid and metals functions
is:
Activity = Intercept + Poly1*COC + Poly2*COC^2 + Poly3*COC^3 +
Poly4*COC^4
The model variables are:
RXR(i).RX1ACT.BLK.METALACTR
88
6 Catalytic Reformer
RXR(i).RX1ACT.BLK.ACIDDEACTINTER
RXR(i).RX1ACT.BLK.ACIDDEACTPOLY1
RXR(i).RX1ACT.BLK.ACIDDEACTPOLY2
RXR(i).RX1ACT.BLK.ACIDDEACTPOLY3
RXR(i).RX1ACT.BLK.ACIDDEACTPOLY4
RXR(i).RX1ACT.BLK.METDEACTINTER
RXR(i).RX1ACT.BLK.METDEACTPOLY1
RXR(i).RX1ACT.BLK.METDEACTPOLY2
RXR(i).RX1ACT.BLK.METDEACTPOLY3
RXR(i).RX1ACT.BLK.METDEACTPOLY4
6 Catalytic Reformer
89
Coke Make
Reformer catalyst is a bifunctional catalyst, and the catalyst activity definition
used in modeling must include separate terms for the metals and acid functions. The activity of the catalyst in a reformer is a function of several factors,
among which are:
l
Water/Chloride environment
Sintering
Catalyst breakage
Items 5 through 9 are basically mechanical changes in the catalyst which occur
primarily during catalyst regeneration. These mechanical changes in the catalyst that affect activity can only be accounted for through direct analysis of the
catalyst, or indirectly from measurement of plant operation. Fortunately, to predict reformer operation on an on-going basis, these changes can be lumped
together in the deactivation model and thus do not create a problem in the reaction modeling.
Permanent catalyst poisons such as those listed in number 4 above are normally very gradual. They can be handled with routine activity model updates,
using the same lump mechanism used for items 5 through 9. When a significant
quantity of permanent poison is deposited on the catalyst over a short period of
time, the deactivation model will need to be updated from plant operating data.
(This is true assuming the unit will remain in service. In most cases where a
90
6 Catalytic Reformer
Coking Mechanism
There are several theories on coke laydown, one or more of them may be correct. The general concept with the greatest acceptance is that coke is formed
from the condensation of polycyclic hydrocarbons. A second generally accepted
concept is that polycyclics are formed from an intermediate olefin created
primarily during the cyclization (and to some degree during isomerization) of
naphthenes from paraffins, and from aromatics. The diagram below is a schematic of the coke make mechanism.
6 Catalytic Reformer
91
l
l
Literature reports give the reaction rates of the paraffin/ naphthene intermediate olefin in terms of the paraffin (or paraffin and naphthene) concentration. For commercial catalytic reformer modeling purposes, it can be
assumed that the coke make is a function primarily of the C5 ring naphthenes
and aromatics.
Coke make in the Reformer is modeled via the reaction of paraffins, C5 ringed
naphthenes, and aromatics to coke via a first order reaction mechanism. All C5
ringed naphthenes share a common activation energy as do the aromatics and
paraffins. The frequency factors vary by carbon number and species. Each
reactor has a coke make activity, as well as a total coke make activity for all
reactors. The reaction rate is in the general form:
RXI
The rates are then used in the reaction equations in the following general
format:
dC
dt
with
dC/dt = coke/time
k
92
6 Catalytic Reformer
C5H6 + CH4 + H2
5N7
C5H6 + CH4 + H2
5N8
C5H6 + C2H6 + H2
5N9
C5H6 + C3H8 + H2
5N10
C10H8 + 6*H2
5N11
N12
N13
N14
A6 + 2*H2
A7 + 2*H2
A8 + 2*H2
A9 + 2*H2
A10
C10H8 + 3*H2
A11
A12
A13
A14
C5H6
0.5*C10H8 + H2
6 Catalytic Reformer
93
Note: The condensation of aromatics to coke results in a net hydrogen production. The
hydrogen consumption shown in these reactions is only to maintain stoichiometric balance during the generation of the coke precursor - C5H5.
Acid
Isomerization
Ring Closure/Open
Ring Expansion
Metal
Pressure Multiplier
X
Dehydrogenation
Hydrogenolysis - Para
Hydrogenolysis - Naph
Hydrocracking
Hydrodealkylation
Polymerization
Also shown in the table above are the reaction mechanisms that are affected by
pressure changes.
The acid and metals activities are independent functions of carbon on catalyst
(COC) expressed as percent of catalyst. The general form for both the acid and
metals activity functions is:
94
Base Temperature
WAIT
6 Catalytic Reformer
WABT
Aromatics Production
Stabilizer Configuration
The stabilizer is a conventional rigorous tower simulation using the Petrofrac
Tower model. A vapor and liquid draw are taken off the overhead receiver, and
the reformate off the reboiler. The overhead receiver pressure and temperature are user-specified, as well as the condenser delta pressure and the
tower delta pressure.
Stage 1 is the condenser. The feed is specified to Stage 11. The reboiler is on
Stage 30. A Murphree efficiency can be specified for Stages 10 through 2 and a
second efficiency for Stages 29 through 12. This gives sufficient freedom to
match actual tower performance.
Control Blocks
Calculation Blocks
Recycle Blocks
Description
RX1HT
RX1
COKESPL
RX1ACT
RX1OPER
Performs a series of calculations such as reactor average bed temperature, catalyst weight and catalyst volume
PINNING
USER3
CCR1
USER3
6 Catalytic Reformer
95
Control Blocks
Block
Description
PISOM
REFCTL
Calculates the reactor inlet temperatures based on the base temperature and individual reactor temperature biases.
LTENDC.F
REACT_A
REACT_B
REACT_C
Description
l
ISOMD2
ISOMD3
ISOMP4
ISOMP5
Calculation Blocks
96
Block
Description
MPROD
Combines duplicates of the net hydrogen and the product separator liquid to form a net reactor yield stream for further analysis
NETCALV
NETCALW
NETH2AM
NETH2AW
NXACALC
6 Catalytic Reformer
Block
Description
OCTSTBV
OPERCAL
REFMRVP
H2HC
NETCAL
Calculates net volumetric yields using user defined gravities for H2,
C1, C2 and O2
HT1TST
HT2TST
HT3TST
HT4TST
Recycle Blocks
Block
Description
BDMAP
First of two blocks that map the component set used in the reactor
section to the component set in the separation section of the Catalytic Reformer.
DMAP
Second of two blocks that map the component set used in the
reactor section to the component set in the separation section of
the Catalytic Reformer.
EFFCLR
Mapping blocks that maps the component set used in the separation
section to the component set in the reactor section of the Catalytic
Reformer.
FLMAP
Mapping blocks that maps the component set used in the separation
section to the component set in the reactor section of the Catalytic
Reformer.
PSEP
PSSPL
Splitter on the product separator vapor to create the recycle and net
hydrogen streams
RCMP2
Recycle compressor
REC1AN
RECSPL
6 Catalytic Reformer
97
Block
Description
RECV
Flash drum used to simulate the pressure drop of the gas stream
between the product separator and the recycle compressor suction
Click Read an Existing Reformer Template to add a Catalytic Reformer operation based on an existing template.
The Catalytic Reformer operation appears on the PFD.
6. Open the Catalytic Reformer property view and make the necessary
changes/specifications/connections for the simulation case.
98
6 Catalytic Reformer
3. Click Next.
4. In the second page of the Reformer Configuration Wizard property view,
specify the parameters of the reactor and heaters in the Catalytic
Reformer.
5. Click Next.
6. In the third and final page of the Reformer Configuration Wizard property view, select or specify a set of calibration factors.
7. Click Done.
HYSYS Refining completes the Catalytic Reformer subflowsheet, based
on the specified information from the Reformer Configuration Wizard,
and opens the Catalytic Reformer subflowsheet environment.
8. In the Catalytic Reformer environment, you can:
o
6 Catalytic Reformer
99
Description
Next>
<Prev
Cancel
Enables you to exit the Reformer Configuration Wizard without saving any
changes or creating a catalytic reformer operation.
Close
Enables you to exit the Reformer Configuration Wizard and keep any specifications or changes made to the catalytic reformer operation.
Done
Enables you to exit the Reformer Configuration Wizard and finish configuring
the catalytic reformer operation.
Configuration (Page 1 of 3)
On the Configuration (1 of 3) page of the Reformer Configuration Wizard, you can specify the basic configuration of the Catalytic Reformer.
1. In the Type ofUnit group, use the radio button to select the type of
reactor.
There are two selections to choose from:
o
Continuous Regeneration
Semi-Regen
2. In the Reactor Section, use the radio button to select the number of
reactor beds:
100
3 Beds
4 Beds
5 Beds
6 Beds
6 Catalytic Reformer
Geometry Page 2 of 3
On the Geometry (2 of 3) page of the Reformer Configuration Wizard property view, you can specify the parameters for the reactor beds in the Catalytic
Reformer.
1. In the Catalyst Void Fraction cell, specify the void fractions of the
catalyst in the reactor.
2. In the Catalyst Bulk Density cell, specify the density of the catalyst in
the reactor.
3. In the Reaction Path Length row, specify the bed length of each
reactor bed.
4. In the Catalyst Weight row, specify the catalyst weight of each reactor
bed.
Note:The number of Bed column vary depending on how many reactor beds you select
in the Configuration page.
Tips:
l
Click the Close button to exit the Reformer Configuration Wizard without saving
any changes.
3. Click Done.
Tips:
l
Click the Close button to exit the Reformer Configuration Wizard without saving
any changes.
6 Catalytic Reformer
101
Description
Delete button
Reformer
Environment
button
Status bar
Displays the status of the reactor section of the catalytic reformer operation.
Ignored check
box
Design Tab
Connecting Streams to the Catalytic Reformer
The Design tab | Connections page enables you to rename the operation and
connect/disconnect streams flowing into and out of the Catalytic Reformer.
To connect streams to the Catalytic Reformer:
1. On the PFD, double-click the Catalytic Reformer icon to open the Catalytic Reformer property view.
2. On the Catalytic Reformer property view, click the Design tab and
select the Connections page.
3. In the Products table(s), under the External column, specify the name
of the product stream, or open the drop-down list and select an existing
stream.
4. In the Reformer Feeds table, under the External column, specify the
name of the feed stream, or open the drop-down list and select an existing stream.
5. Under the Feed Type column, select the appropriate cell and open the
drop-down list to select the feed type associated to the feed stream.
102
6 Catalytic Reformer
Tips:
l
You can specify/modify the name for the Catalytic Reformer operation in the
Name field.
Click the Feed Type Library button to access the Feed Type Library Property
View and modify/configure the feed type and data of a selected stream.
Click the Import button to import feed types into the current feed stream.
Click the Export button to export feed type from the current feed stream.
Click the Delete button to delete feed type from the current feed stream.
4. In the Kinetic Tuning table, you can view the following calibration
factors:
6 Catalytic Reformer
103
DP Factors
Pinning Coefficients
Feed
Reactor Control
Catalyst
ProductHeater
Solver Options
Solver Console
Advanced
EO Variables
Recontactor
104
6 Catalytic Reformer
stream in the appropriate cell under the Volume Flow, Mass Flow, or
Std Vol Flow column respectively.
4. Specify the temperature of the feed stream in the appropriate cell under
the Temperature column.
5. Specify the pressure of the feed stream in the appropriate cell under the
Pressure column.
Note:The last row displays the total for each flow rate type.
WAIT [C]
WABT [C]
C5+ RON
C6+ RON
6 Catalytic Reformer
105
106
For CCR reactor, you can specify the regenerator condition, and
either specify the catalyst circulation rate or the coke on catalyst weight %.
Object
Description
CatalystCirculation
Rate field
Coke on Catalyst
(wt%) rows
Coke Laydown
Rate (kg/h) rows
Percent Pinning
(%) rows
For the Semi-regen reactor, you can specify the start and end
time for the reaction, the initial coke on catalyst, and the coke
on catalyst equilibrium distribution factor.
Object
Description
Simulation
End/Start
Times table
6 Catalytic Reformer
COC at Start of
Simulation
table
Equilibrium
Distribution
Factors table
Average COC
table
Rate of Coke
Production
table
Product Heater
The Reactor Section tab | Product Heater page of the Catalytic Reformer
enables you to specify the temperature or heat duty of the heater, and the outlet stream pressure or pressure difference of the heater.
l
6 Catalytic Reformer
107
behavior and requires that spec groups are complete before solving.
6. In the SQP Hessian Parameters group, specify the following:
o
From the Initialization drop-down list, specify how the Hessian is initialized.
Option
Description
Normal
(Default)
Hessian initialized with identity matrix. This setting balances efficiency and robustness. It is well suited for general purpose optimization problems. Typical applications
are offline optimization and online problems that start
very far from a solution.
Aggressive
Scaled
Advanced
Hessian initialized with 2nd order information. Recommended for problems with many Degrees of Freedom at
solution and/or quadratic objective function. Ideal for
data reconciliation problems, both online and offline.
108
Description
Normal
(Default)
Exact
A well-known exact penalty line search. It is too conservative for most practical problems.
Residual
A proprietary line search designed to initially favor the convergence of residuals over the objective function improvement.
6 Catalytic Reformer
Square
From the Step Control drop-down list, specify how large the
steps will be.
Option
Description
Normal
(Default)
Aggressive
Conservative
9. In the Failure Recovery Action group, you can specify which action
the solver should take in the event of failure:
o
Do nothing
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
6 Catalytic Reformer
109
1. On the PFD, double-click the Catalytic Reformer icon to open the Catalytic Reformer property view.
2. On the Catalytic Reformer property view, click the Reactor Section tab
and select the Solver Console page.
Note:Solver messages and commands appear in the Simulation Engine Message and Script Commands field.
3. In the Command field, enter the script command you want to run.
4. Press Enter.
Tips:
l
To clear the commands on the Solver Console page, click the Clear Output button.
To clear the command in the Command field, click the Clear Command button.
110
6 Catalytic Reformer
Intercept
Intercept
You can sort the variable list by any attribute in ascending and descending order.
To sort the list of variables by any attribute, double-click the desired
attribute's column header.
To sort a subset of the variable list, check the variable in the Marked
column and double-click the Marked column header.
If any variable attributes have been changed, their Modified entry is selected.
To sort by Modified, double-click the Modified column header.
Configuring Recontactors
To configure the recontactor of the Catalytic Reformer:
1. In the Main environment, press CTRL P to open the PFD property view.
2. On the PFD property view, double-click the Catalytic Reformer icon to
open the Catalytic Reformer property view.
3. On the Catalytic Reformer property view, click the Reactor Section tab
and select the Recontactor page.
4. Along the Outlet Pressure row, specify the pressure value for the low
and high pressure in the appropriate cells.
5. Along the Inlet Stream DP row, specify the pressure difference for the
6 Catalytic Reformer
111
Zone Pressures
Specs
Note:If the Catalytic Reformer does not have a stabilizer tower, this tab is blank.
To specify the zone pressure in the stabilizer tower of the Catalytic Reformer:
1. On the PFD, double-click the Catalytic Reformer icon to open the Catalytic Reformer property view.
2. On the Catalytic Reformer property view, click the Stabilizer Tower
tab and select the Zone Pressures page.
3. Under the Zone Top Pressure column, specify the pressure value for
each zone in the stabilizer tower.
4. In the Bottom Pressure cell, specify the bottom pressure of the stabilizer tower.
To specify the TBP cut point of the stabilizer tower of the Catalytic Reformer:
112
6 Catalytic Reformer
1. On the PFD, double-click the Catalytic Reformer icon to open the Catalytic Reformer property view.
2. On the Catalytic Reformer property view, click the Stabilizer Tower
tab and select the Specs page.
3. In the Spec Option group, select the TBP Cut Point radio button.
4. In the TBP Calculation Method drop-down list, select the calculation
method for the TBP cut point.
5. Under the TBP Cut Point column, specify the boiling point temperature
for each cut point.
Note:
l
The Molar Feed Fraction column displays the feed fraction for each cut point.
The TBP 5% column displays the boiling point temperature at 5 percent of each
cut point.
The TBP 95% column displays the boiling point temperature at 95 percent of
each cut point.
To specify the Product Flow Fraction in the stabilizer tower of the Catalytic
Reformer:
1. On the PFD, double-click the Catalytic Reformer icon to open the Catalytic Reformer property view.
2. On the Catalytic Reformer property view, click the Stabilizer Tower
tab and select the Specs page.
3. In the Spec Option group, select Product Flow Fraction radio button.
4. In the Basis group, select one of the following bases you want to specify
the feed fraction in: Molar, Mass, or Liquid Volume.
5. Under the Feed Fraction column, specify the fraction of the feed
stream divided into each product stream.
Note:The Bottom Spec group displays the calculated (Actual) bottom stream flow rate
and the minimum required (Minimum) bottom stream flow rate. The minimum flow rate
is based on the Feed stream flow rate and entering temperature. If the minimum flow
rate is more than the bottom flow rate, the column will not converge.
Summary
Feed Blend
Product Yields
Product Properties
Reactor Section
Heater
6 Catalytic Reformer
113
Recontactor
Product Streams
mass flowrate
components
volume flowrate
paraffins
standard volume
flowrate
naphthenics
moles flowrate
aromatics
molecular weight
D86 Initial
point
specific gravity
D86 cut
points
API gravity
TBP Initial
point
TBP cut
points
114
6 Catalytic Reformer
Grouped
Detailed
Fractionated
Note:If the Catalytic Reformer contains a stabilizer tower, the product stream properties
from the stabilizer tower also appears on the Product Yields page.
Grouped Yields
If you select the Grouped radio button, the Grouped Yields table displays the
weight % and volume % values for the following properties:
l
Total paraffins
Total olefins
Total naphthenics
Total aromatics
Total C4 plus
Total C5 plus
Total C6 plus
Total C8 aromatics
Total C5 paraffins
Total C6 paraffins
Total C7 paraffins
Total C8 paraffins
Total C9 paraffins
The Weight Ratio table displays the isomer to normal weight ratios for the following components:
6 Catalytic Reformer
115
A8 Para-xylene Percent
A8 Meta-xylene Percent
A8 Ortho-xylene Percent
A8 Ethyl-benzene Percent
Detailed Yields
If you select the Detailed radio button, the Detailed Yields table displays the
weight % and volume % values for the following properties:
116
H2
P1
P2
OL2
P3
O3
IP4
NP4
O4
IP5
NP5
O5
5N5
MBP6
SBP6
NP6
O6
5N6
A6
6N6
MBP7
SBP7
NP7
O7
6 Catalytic Reformer
5N7
A7
6N7
MBP8
SBP8
NP8
O8
5N8
ETHYLBEN
O-XYLENE
M-XYLENE
P-XYLENE
6N8
IP9
NP9
5N9
A9
6N9
IP10
NP10
5N10
A10
6N10
IP11
NP11
5N11
A11
6N11
P12
N12
A12
P13
N13
A13
P14
N14
A14
6 Catalytic Reformer
117
Fractionated Yields
If you select the Fractionated radio button, the Fractionated Yields table
displays the weight % and volume % values for the following properties:
l
H2
P1
P2
OL2
P3
OL3
P4
NP4
OL4
IP5
NP5
OL5
MBP6
SBP6
NP6
OL6
5N6
A6
6N6
Reformate
Note: If the Catalytic Reformer does not contain a stabilizer tower, the Fractionated
option displays a blank page.
118
C6+ RON
C5+ MON
6 Catalytic Reformer
C6+ MON
4. In the Stabilizer Bottoms table, you can view results for the following:
o
RON
MON
RVP [kPa]
API Gravity
Molecular Weight
5. In the Stabilizer Overhead Liquid table, you can view results for the
following:
o
Molecular Weight
API Gravity
6 Catalytic Reformer
Inlet Temperature
Outlet Temperature
Inlet Pressure
Outlet Pressure
Delta P: Pressure difference between the inlet stream and outlet stream.
119
For Booster Compressor: inlet stream moles flow rate, inlet stream temperature, inlet stream pressure, outlet stream temperature, outlet
stream pressure, and gas power.
For Recontactors: inlet vapour temperature, inlet vapour temperature,
inlet vapour delta pressure, inlet liquid moles flow rate, inlet liquid temperature, inlet liquid pressure, inlet liquid delta pressure, heat loss,
product temperature, product vapour fraction, Murphree efficiency,
vapor mass, vapor moles, liquid temperature, liquid pressure, and liquid
H2.
The following properties appear for the H2 Vent at low pressure: H2 to vent
splitter, H2 to HP recontactor drum, fraction of H2 to HP recontactor drum, H2
Vent stream, and fraction of H2 to Vent H2.
120
6 Catalytic Reformer
Click the Delete button to delete the reactor in the Catalytic Reformer.
Click the Ignore check box to ignore the reactor during simulation calculation of
the process flow diagram. Clear the Ignore check box to restore the reactor into
the simulation calculation.
6 Catalytic Reformer
121
The Design tab contains the features used to configure the reactor section of
the Catalytic Reformer operation. These features are grouped into the following
pages:
l
Configuration
Catalyst Loadings
Notes
Note:Each column in the table contains the parameter information for each
reactor bed.
122
6 Catalytic Reformer
Library
Properties
Note: You can also access the features in the Feed Data tab by clicking the Feed Type
Library button in the Connections page of the Catalytic Reformer property view.
Description
Feed Types
group
Displays the list of feed data types available for the reactor.
Import button
Enables you to import a feed data from a file. The feed data are saved in
*.csv type files.
Export button
Enables you to export the selected feed data (from the Available
Feed Types group) into a *.csv file. The exported feed data can be
imported into a different applicable operation.
Delete button
Enables you to delete the selected feed data in the Available Feed
Types group.
Properties of
Selected
Feed Type
table
Note: You can also access the features on the Feed Data tab by clicking the Feed Type
Library button on the Design tab | Connections page of the Catalytic Reformer property view.
6 Catalytic Reformer
123
Tip:You can provide a description of the new feed type by entering the information in the Description field.
5. In the Kinetic Lump Weight Percents group, enter the weight percents for the kinetic lumps in the new feed type.
Tip:You can normalize the total percentage value of the Kinetic Lump Weight Percents to 100 by clicking the Normalize button.
6. In the Methyls and Biases group, enter the methyl elements specifications and boiling point and Ca biases for the new feed type.
Tip:You can click the Calculate Biases button to calculate the bias values based
on the specified bulk properties.
7. Click the Close icon to close the Feed Type property view and save the
new feed type into the Catalytic Reformer operation.
The new feed type appears in the Available Feed Types list on the
Library page of the Reactor Section property view.
Tip:To delete an existing feed type, select the feed type in the Available Feed
Types list and click the Delete button.
In the Reactor Section property view, click the Feed Data tab,
select the Library page, in the Available Feed Types list
select the feed type you want to modify, and click Edit button.
2. In the Name field, enter the modified name for the feed type.
Tip:You can modify the description of the feed type by entering the information in
the Description field.
Note:
o
Date Created field displays when the feed type was created.
Date Modified field displays when the last time the feed type properties was modified.
3. In the Kinetic Lump Weight Percents group, modify the weight percents
for the kinetic lumps in the feed type.
Tip:You can normalize the total percentage value of the Kinetic Lump Weight Percents to 100 by clicking the Normalize button.
4. In the Methyls and Biases group, modify the methyl elements specifications and boiling point and Ca biases for the feed type.
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6 Catalytic Reformer
Tip:You can click the Calculate Biases button to calculate the bias values based
on the specified bulk properties.
5. Click the Close icon to close the Feed Type property view and save the
changes made to the feed type into the Catalytic Reformer operation.
Tip:You can click the Delete button to close the Feed Type property view and
delete the feed type.
2. Click the Feed Data tab, and select the Library page.
3. Click the Import button.
The Available Feed Types property view appears.
4. In the Available Feed Types property view, browse for the *.csv file
that contains the feed type you want to import.
5. Select the file you want and click the Open button.
The imported feed type now appears in the Available Feed Types list
on the Library page.
2. Click the Feed Data tab, and select the Library page.
3. In the Available Feed Types list, select the feed type you want to
export.
4. Click the Export button.
The File selection for exporting Feed Types property view appears.
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125
5. Browse to the folder location where you want to store the feed type file.
6. In the File Name field, enter the name of the *.csv feed type file.
7. Click the Save button.
The selected feed type is saved into the *.csv file, and can be retrieved
for later use in other simulation cases.
2. Click the Feed Data tab, and select the Library page.
3. In the Available Feed Types list, select the feed type you want to
clone.
4. Click the Clone button.
The Feed Type property view appears.
5. In the Feed Type property view, make any modifications you want to the
cloned feed type.
For example, you can change the cloned feed type name by entering the
new name in the Name field.
6. When you have completed the modifications, click the Close icon to exit
the Feed Type property view.
The cloned feed type appears in the Available Feed Types list of the
Library page.
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Note:
o
The Feeds list displays the names of all the virtual and real
streams connected to the reactor.
You can only add virtual type streams on the Properties page.
Tip: You can delete an existing stream by selecting the stream from the Feeds list
and clicking the Delete button. If the selected stream is real, then both real and
virtual stream (connected to the real selected stream) are deleted.
BulkProperties: Lets you specify bulk properties of the selected feed type.
GCFull: If you select this option, you can specify values for all
of the components, but some may be double-counted.
GCRecommended
If you select the Turn Off GCEdit Box check box, if you perform a case study, the case study automatically accepts all values specified in the table below.
Feeds
Reactor Control
Catalyst
ProductHeater
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127
Solver Options
Solver Console
Advanced
Octane Curves
EO Variables
Recontactor
C5+ RON
C6+ RON
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6 Catalytic Reformer
Changing specifications results in clearing and recalculating all previously calculated values from the Temperature matrix. Copy Data serves as a notepad to
copy the current data from the Reactor Temperature Specification section. This
lets you change specifications (for example, delete WAIT and input a WABT
instead) and retain previously known values in order to compare or restore the original values.
Recycle Gas Location Options opens an input View which lets you assign a fractional value and a flow rate formula for each of the reactors for recycle gas.
For CCR:
o
For semi-regen:
o
In the COC at Start of Simulation table, specify the COC for each
reactor bed at the start of the simulation.
In the Equilibrium Distribution Factor table, specify the COC equilibrium distribution factor for each reactor bed.
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129
3. In the Enter Script Command field, enter the script command you
want to run.
4. Click Run Command.
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6 Catalytic Reformer
Tips:
l
To clear the commands in the Simulation Engine Message and Script Commands field, click the Clear Message button.
To retrieve previous command, click the Get Prev. Command button. The previous command appears in the Enter Script Command field.
To retrieve next command, click the Get Next Command button. The next command appears in the Enter Script Command field.
To clear the command in the Enter Script Command field, click the Clear Command button.
Intercept
Intercept
Note:The options/features in the Advanced page are meant for expert users who want
to adjust the Catalytic Reformer operation performance to match their plant data.
Octane Curves
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131
Use this page to set the RON and MON Blending Numbers for each component to
change the octane curve.
EO Variables Page
This grid lists all of the variables and their attributes. It may be used to change
the attributes of a variable. Whenever an attribute is changed, its background
color becomes yellow.
You can sort the variable list by any attribute in ascending and descending
order.
l
If any variable attributes have been changed, their Modified entry becomes
checked. To sort by Modified, double-click the Modified column header.
Configuring Recontactors
The Recontactor page enables you to configure the recontactor in the reactor.
To configure the recontactor in the Catalytic Reformer:
1. On the Reactor Section property view, click the Operation tab.
2. Select the Recontactor page.
3. In the Booster Compressor 1 table, specify the following variables in the
appropriate cells:
o
5. In the Low Pressure Recontactor Drum table, specify the following variables in the appropriate cells:
o
pressure drop
6. In the High Pressure Recontactor Drum table, specify the following variables in the appropriate cells:
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6 Catalytic Reformer
pressure drop
Note:If the Catalytic Reformer does not contain a recontactor, then this page is
blank.
Results Tab
Summary Page
On the Catalytic Reformer Reactor Section view, the Results tab | Summary
page displayed the calculated results for the Catalytic Reformer, including the
following calibration calculation summary variables:
l
WAIT
RON
Grouped
Detailed
Note:If the Catalytic Reformer contains a stabilizer tower, the product stream properties
from the stabilizer tower also appear on the Product Yields page.
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Reactors Page
The Reactors page displays the key simulation results of the riser and reactor.
To access the Reactors page:
1. On the Reactor Section property view, click the Results tab.
2. Select the Reactors page.
Heaters Page
The Heaters page displays the calculated results of the fired duty and
absorbed duty of each heater in the Catalytic Reformer.
To access the Heaters page:
1. On the Reactor Section property view, click the Results tab.
2. Select the Heaters page.
Recontactor Page
The Recontactor page displays calculated results of the recontactor.
Note:If the Catalytic Reformer does not have a recontactor, this page is blank.
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6 Catalytic Reformer
Calibration Environment
The Calibration environment enables you to perform calibration for the Catalytic Reformer operation.
After calibrating the operation to the desired performance, you can export the
new parameter/ variable values to the Catalytic Reformer operation in the simulation environment and view the new results.
To access the Calibration environment:
l
6 Catalytic Reformer
135
The features/options available in the first four tabs are available for you
to make modifications to the existing Catalytic Reformer, if you
want/need to:
o
In the Design tab, you can make modifications to the configuration and geometry parameters of the reactor.
In the Feed Data tab, you can make modifications to the feed
stream.
In the Operation tab, you can make modifications to the overall operation performance of the Catalytic Reformer.
4. Click the Calibration Control tab, and specify the parameter and
objective function values for the calibration run. A calibration run fits the
models kinetic rate constants and base operating data to match an
observed process operation, feed properties, and product yields. This is
also called a tuning run.
5. Click the Run Calibration button.
o
136
If you only have one data set, the Validation Wizard property
view appears.
On the Validation Wizard property view, validate the data set
6 Catalytic Reformer
If you have more than one data set, the Select Data Sets for Calibration property view appears.
On the Select Data Sets for Calibration property view, select
and validate the data set you want, and click the Run Calibration button to continue with the calibration run.
6. After the calibration run has finish, click the Analysis tab to view the calibration run results.
Tips:
o
Click the Push Data to Simulation button to export the current calibration results to the Catalytic Reformer variables in the simulation
case.
Click the Pull Data from Simulation button to import the Catalytic
Reformer variable values, from the simulation case, into the Calibration
property view.
Click the Return to Simulation button to exit the Calibration environment and return to the Catalytic Reformer environment.
If the Total cell under the Mass Flow column (in the Feed Group)
equals the Total cell under the Measured Mass Flow column (in the
Product Group), the current data set is valid and is used in the calibration
run. A calibration run fits the models kinetic rate constants and base
operating data to match an observed process operation, feed properties,
and product yields. This is also called a tuning run.
If the Total cell under the Mass Flow column (in the Feed Group) does
not equal the Total cell under the Measured Mass Flow column (in the
Product Group), you can assign a bias feature to manipulate/adjust the
mass flow rate of the product stream whose measured data are less reliable.
To assign the bias feature to a product stream, select the appropriate
check box under the Assign Bias column. Clear the check box to
remove the bias feature.
Thus the adjusted data set is valid and used in the calibration run.
The Validation Wizard view appears when one of the following occurs:
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137
The Run Calibration button (in the Calibration property view) is clicked
and the Calibration property view only has one data set. The Run Calibration button is unavailable until all of the necessary calibration input
is complete.
The check box under the Include column (in the Select Data Sets for Calibration property view) is selected.
Notes
l
HYSYS always validates the selected data set before the calibration is actually run.
The coke mass flow and hydrogen in coke are also calculated from flue gas analysis.
Any unreasonable values indicate that the flue gas analysis is questionable and
you should not proceed with the calibration.
Reactor
Advanced
Kinetic Factors
Stabilizer
You can edit the following variables in the Factor Set property view:
l
138
Name of the calibration factor set: In the Factor Set group, enter the
name of the calibration factor set in the Name field.
Description of the calibration factor set: In the Factor Set group, enter
information about the calibration factor set in the Description field.
reactor variables
stabilizer variables
6 Catalytic Reformer
Note:
l
The Date Created and Date Modified fields display the date and time the calibration factor set was created and last modified.
If the Catalytic Reformer does not contain a stabilizer tower, than the Stabilizer
page appears blank.
From the Reactor Section view, from the reactor's ribbon tab,
click Select CalibrationFactors. On the Calibration Factor
Set dialog box, click the Library button.
-or-
In the Reformer Configuration Wizard property view, go to the Calibration Factors (3 of 3) page and click the Library button.
In the Catalytic Reformer Property View, select the Design tab | Calibration Factors page, and click the Calibration Factors Library
button.
In the Catalytic Reformer Environment, from the Reformer ribbon tab,
select the Select CalibrationFactors button. Click the Library button
on the Calibration Factor Set property view.
The following table lists and describes the options available on the Calibration
Set Library property view:
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139
Object
Description
View/Edit button
Enables you to view or modify the data of the selected factor set
in the Available Calibration Factor Sets list.
Add button
Enables you to add a new factor set and access the Factor Set
Property View.
Delete button
Clone button
Import button
Export button
Enables you to export/save the selected factor set (in the Available Calibration Factor Sets list) to a file *.csv.
HYSYS provides a default calibration factor set with values in the Calibration
Set Library.
The calibration factor values, in the Default calibration factor set, are read
only.
To modify the calibration factors, you must make a clone of the Default Calibration Factor set, and modify the calibration factor values in the cloned set.
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6 Catalytic Reformer
Factors.
3. On the Calibration Factors page, click Calibration Factors Library.
4. On the Calibration Set Library dialog that appears, select the Calibration Factor set you want to export.
5. Click Export.
6. On the File selection for exporting Factor Sets dialog that appears,
browse to the folder to which you want to export the Calibration
Factor set.
7. If you want, in the File name field enter a new name for the exported
Calibration Factor set.
8. Click Save.
The Calibration Factor set is exported.
Reactor Parameters
The Reactor page of the Factor Set property view allows you to access the
Reactor Factors group and specify variable values associated with the
reactor.
To edit the reactor parameters of a factor set:
1. Open the Factor Set property view.
Note:You cannot edit the default calibration factor set provided by HYSYS Refining.
Tips:
o
You can modify the name of the calibration factor set by entering the
new name in the Name field located in the Factor Set group.
You can modify the description of the calibration factor set by entering
the information in the Description field located in the Factor Set group.
Advanced Options
The Advanced page of the Factor Set property view allows you to access the
Advanced Factors group and specify variable values associated with the
advanced options.
To edit the advance options of a factor set:
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141
You can modify the name of the calibration factor set by entering the
new name in the Name field located in the Factor Set group.
You can modify the description of the calibration factor set by entering
the information in the Description field located in the Factor Set group.
Stabilizer Parameters
The Stabilizer page of the Factor Set property view allows you to access the
Fractionator Cuts group and specify variable values associated with the stabilizer tower.
To edit the stabilizer parameters of a factor set:
1. Open the Factor Set property view.
Note:
o
Tips:
o
You can modify the name of the calibration factor set by entering the
new name in the Name field located in the Factor Set group.
You can modify the description of the calibration factor set by entering
the information in the Description field located in the Factor Set group.
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6 Catalytic Reformer
2. In the Select Data Sets for Calibration property view, select the check
box, under the Include column, associated to the data set you want to
use.
Each time the check box is selected, the Validation Wizard property view
appears.
3. In the Validation Wizard property view, validate the data set and click
OK.
Under the Status column, the status of the data set displays OK.
Note:If the data set is not ready for the calibration run (for example, the status
displays Input Incomplete), the check box beside the data set is inactive.
4. Repeat steps 2 and 3 till you have selected and validated all the data set
you want to include in the calibration run.
5. On the Select Data Sets for Calibration view, click the Run Calibration
button to begin the calibration run.
Note:The Run Calibration button is inactive until you select a data set for the calibration run.
Tips:
l
Click the Stop button to stop the calibration run during mid-calculation.
Click the Close button to exit the Select Data Sets for Calibration view.
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144
6 Catalytic Reformer
Description
Run Calibration
button
Data Set
drop-down
list
Enables you to select different data sets for entering the data or viewing
the results for the calibration or the prediction run.
Manage
Data Sets
button
Enables you to access the Data Set Manager property view to manage
the data set.
Push Data
to Simulation button
Enables you to export input data from the current data set in the calibration property view to the property view in the Catalytic Reformer
environment.
Pull Data
from Simulation button
Enables you to import input data from the property view in the Catalytic
Reformer environment into the current data set in the Calibration property view.
6 Catalytic Reformer
Any existing simulation data will be overwritten with the current calibration data.
Any existing calibration data will be overwritten with the current simulation data.
145
Return to
Simulation
button
Enables you to exit the Calibration environment and return to the Catalytic Reformer environment.
Status bar
Catalyst Weight
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6 Catalytic Reformer
Library
Properties
Note:Any modifications to the variables in this tab will only affect the calibration run calculation. A calibration run fits the models kinetic rate constants and base operating data
to match an observed process operation, feed properties, and product yields. This is also
called a tuning run.
Note:
o
The Feeds list displays the names of all the virtual and real
streams connected to the reactor.
You can only add virtual type streams on the Properties page.
Tip: You can delete an existing stream by selecting the stream from the Feeds list
and clicking the Delete button. If the selected stream is real, then both real and
virtual stream (connected to the real selected stream) are deleted.
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147
BulkProperties: Lets you specify bulk properties of the selected feed type.
GCFull: If you select this option, you can specify values for all
of the components, but some may be double-counted.
GCRecommended
If you select the Turn Off GCEdit Box check box, if you perform a case study, the case study automatically accepts all values specified in the table below.
Feeds
Reactor Control
Catalyst
Recontactor
Product Heater
Stabilizer
Solver Options
Solver Console
Advanced
Note:Any modifications to the variables in this tab will only affect the calibration run calculations. A calibration run fits the models kinetic rate constants and base operating data
to match an observed process operation, feed properties, and product yields. This is also
called a tuning run.
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6 Catalytic Reformer
The last row displays the total for each flow rate type.
You can modify the overall pressure of the blended feed in the appropriate cell along the Blended row.
C5+ RON
C6+ RON
4. In the Hydrogen Recycle table, modify the recycle compressor flow rate
and the H2HC ratio.
5. In the Product separator table, modify the temperature and pressure in
the separator.
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149
For CCR:
o
Percent pinning
For semi-regen:
o
Note:If the Catalytic Reformer does not contain a recontactor, this page is blank.
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6 Catalytic Reformer
Running Pre-Calibration
You can also click the Run Pre-Calibration button (accessed from the
Reformer ribbon tab) to run the calibration without setting the objective function. It is a useful method to run the calibration without changing the degrees of
freedom. If you select the Run Pre-Calibration option, the model initializes
based on the current factor set and operating conditions. For further details,
refer to Running Pre-Calibration for the Catalytic Reformer.
EO Solver Reports
The EO solver report files for reactor models are written to the Temp directory.
6 Catalytic Reformer
151
3. In the Enter Script Command field, enter the script command you
want to run.
4. Click Run Command.
Tips:
l
To clear the commands in the Simulation Engine Message and Script Commands field, click the Clear Message button.
To retrieve previous command, click the Get Prev. Command button. The previous command appears in the Enter Script Command field.
To retrieve next command, click the Get Next Command button. The next command appears in the Enter Script Command field.
To clear the command in the Enter Script Command field, click the Clear Command button.
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6 Catalytic Reformer
The Measurement tab contains features used to configure the reactor, compressor, recycle stream, and product stream properties. The features are
grouped into the following pages:
l
Operation
Products
Analysis
Note:Any modifications to the variables in this tab will only affect the calibration run calculations. A calibration run fits the models kinetic rate constants and base operating data
to match an observed process operation, feed properties, and product yields. This is also
called a tuning run.
Description
Inlet Pressure
Pressure
Drop
Delta T
Description
Discharge Pressure
Suction Pressure
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153
Description
Gas Rate
row
Enables you to modify the gas flow rate of the applicable product
stream.
Liquid Rate
row
Mass Rate
row
RON row
MON row
Composition
row
Component
rows
percentage in moles
percentage in weight
percentage in volume
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6 Catalytic Reformer
The Ring Generation group displays the flow rate for the number of carbons in the feed and reformate stream, and the percentage change between the two streams.
The Light Ends Ratios group displays the molar flow rate of
the light end components in the product stream, percentage
value of the light ends in the product stream, and the Iso to
Normal butane ratio.
Parameter
Objective Function
Note:Any modifications to the variables in this tab will only affect the calibration run calculation. A calibration run fits the models kinetic rate constants and base operating data
to match an observed process operation, feed properties, and product yields. This is also
called a tuning run.
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155
4. In the Initial Value column, you can change the default values for all of
the Included control parameters. You must specify a value greater than
or equal to 0.
5. In the Lower Bound column, specify the lower bound values for the control parameters. You must specify values greater than or equal to 0.
6. In the Upper Bound column, specify the upper bound values for the control values. You must specify values greater than the Lower Bound values.
156
Calibration Factors
Mass Balance
Summary
Feed Blend
Product Yields
Reactors
Heater
Recontactor
Stabilizer
Product Streams
6 Catalytic Reformer
Note:The calculated variable values in this tab are limited to the Calibration environment.
To save the current calibration factor set into the current simulation, click the
Save for Simulation button.
The Save for Simulation button is only available if the current calibration run
was successfully calculated.
To export the current calibration factor set into a file, click the Export button. The
Export button is only available if the current calibration run was successfully calculated.
To manage the calibration factor set, click the Calibration Factors Library button to access the Calibration Set Library property view.
Note:The calculated variable values in this page are limited to the Calibration environment.
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157
WAIT
RON
Grouped Yield
Detailed Yield
Note:If the Catalytic Reformer contains a stabilizer tower, the product stream properties
from the stabilizer tower also appear on the Product Yields page.
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159
Temperature
Pressure
Composition
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7 Assay Manipulator
The Assay Manipulator allows you to change the petroleum assay properties of
a material stream, without the need to supply any theoretical equations or calculations to obtain the property values.
The common reasons to change the petroleum assay property values are:
l
The Assay Manipulator supplies two ways to modify the petroleum assay properties:
l
7 Assay Manipulator
161
Tip: Click the Ignored check box to tell HYSYS to ignore the unit operation when solving
the simulation.
Assay Manipulator
PropertyView
From the PFD, double-click the Assay Manipulator icon. The Assay Manipulator
property view appears. From here you can modify any of the assay manipulators properties.
There are three common objects at the bottom of the Assay Manipulator property view. The following table describes these objects:
Object
Description
Delete
button
Status
bar
Displays the current status of the operation (for example, missing information or errors encountered during calculation).
Ignored
check
box
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7 Assay Manipulator
5. In the Outlet drop-down list either type in the name of the stream or if
you have pre-defined your stream select it from the drop-down list.
6. In the Fluid Package drop-down list, select the fluid package you want
to use for the air cooler. The fluid package that is associated with the
flowsheet is selected by default.
Assay Tab
Specifying Properties for Shift or Change
1. From the PFD, double-click the Assay Manipulator icon. The Assay Manipulator property view appears.
2. Click on the Assay tab.
3. Click on the Options page.
4. Under the Property column, use the drop-down list to select the petroleum assay properties you want to manipulate.
5. Under the Options column, use the drop-down list to select the type of
changes that will be used to manipulate the selected petroleum assay
property.
There are two types of changes available:
o
Shift Prop. This option allows you to shift all the values in the
selected petroleum assay property to meet a certain target bulk
value.
Note: You can only add one type of modification method for each property.
6. Repeat step 4 and 5 until you have added all the petroleum assay properties that you want to manipulate.
7 Assay Manipulator
163
If none of the petroleum assay properties in the Options page have the Change
Prop option, the drop-down list in the Assay Properties group will be blank.
The plot beside the table displays the original and modified petroleum assay property values.
If you select the User Table check box, you can change the curve using the
User Property Table instead. The User Table selection changes how you
shift properties, replacing the table on the Change Props page with a property
that allows more customized input for fitting your own curve.
Whether or not you opt to use the User Property Table depends on the scale of
your desired changes to the properties. Typically, you will:
l
Modify portions of the curve using the table on the Change Props tab.
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7 Assay Manipulator
Select the Use Feed check box to use the property values from
the feed stream.
Use the drop-down list in the Use Assay cell to select the property values from a petroleum assay.
Note: You cannot select a different assay as the base point(s) if you have selected
the Use Feed check box.
6. In the Targets table, specify the shift in value for the selected property
by doing one of the following:
7 Assay Manipulator
Type the amount of shift for the product stream in the Product
cell.
Type the difference between the feed value and the target value
in the Prod Feed cell.
165
Notes:
l
The Calculated Values table displays the calculated values based on the information entered in the Reference and Targets tables.
The plot displays both the original and manipulated petroleum property values.
You can choose to modify the component values of liquid density and/or molecular
weight or the bulk liquid density and/or molecular weight. In this option, HYSYS
will re-estimate the physical properties of all the components, such as critical temperature, critical pressure, and so forth.
Light Ends radio button. Select this radio button to specify the
light ends component fractions. In the left drop-down list,
select mass or volume for the component fraction. In the table,
enter the component fraction for the light ends.
6. From the left drop-down list, select between four different temperature
data that affects the percent yield:
o
TBP
ASTMD86
D1160
D2887
7. From the right drop-down list, select Mass or Volume for the percent
yield or composition fraction.
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7 Assay Manipulator
TBP
ASTMD86
D1160
D2887
2. From the right drop-down list, select Mass or Volume for the percent
yield or composition fraction.
3. In the Yield column, specify the mass or volume percent yield associated to the specified temperature.
4. In the right column, specify the temperature of the selected option from
the Left drop-down list.
Note:The changes in the product composition are displayed in the Composition vs. NBP
plot. The plot displays both feed and product streams data, so you can observe the
changes.
Mass
Volume
Mole
3. In the table, specify the mass, volume, or mole fraction of the light ends
composition.
Note:The changes in the product composition are displayed in the Composition vs. NBP
plot. The plot displays both feed and product streams data, so you can observe the
changes.
7 Assay Manipulator
167
Notes
l
168
If you enter light end information which is not consistent with distillation
data, it is possible to have a negative composition for some hypothetical
components.
It is not recommended to have heavier pure components (C5 onwards),
instead it is recommended to use GC properties.
It is recommended that a component list be ordered by boiling point in
ascending order. Use the Sort List button in the Components List View to
move an out-of-order component to the proper position.
7 Assay Manipulator
The Petroleum Shift Reactor unit operation supports efficient modeling of reactors by using data tables to perform shift calculations. The operation can be
used for complex reactors where no analytical model is available, or where
models that are too computationally expensive.
Shift reactor models are empirical models representing the response of the output of a reactor to changes in its operating conditions. These models are not
based upon the underlying scientific theory for the reactor, or upon the chemistry of the reaction, but simply upon an observation of how the output
responds to certain stimuli. The models are generally linear and are only applicable within a fairly tight range of a particular base condition.
The petroleum yield shift unit operation calculates the flow rates of a defined
set of product streams based upon the difference between the current value of
an independent variable and a supplied base value. Dependent variables other
than the flow rates can also be specified.
The following general equations are used for the calculation of a dependent variable y :
k
yk = yk0 + dyk , j
j=0
Where:
yk0
= base value for dependent variable y at base conditions of the independent varik
ables x .
0
169
y
/x
xj
170
Feed
Independent Param
None: Select this option if you want to exclude this yield from
mapping inRefSYS.
Feed
Product
171
IBP
FBP
ProductTemp
Note: For pure products, select the IBP and FBPfrom the drop-down lists of available pure components. For wide cuts, type the temperature range.
4. In the Flow Rate Basis column, select the units for each feed or
product.
5. ClickNext.
Design Tab
Specifying PSRConnections
The Connections page lets you configure the material and utility streams flowing in and out of the reactor.
To specify PSRconnections:
172
You can adjust the model's smc/cme coefficients before exporting it.
Without PIMSSubmodel
The following table lists and describes the options available in the Model Data
page if you did not import a PIMSsubmodel:
173
Object
Description
Independent
Vars button
Reactor Params
button
Independent Vari- All remaining columns in the table. The valable / Parameter
ues in these columns (except the first row)
columns
define the rate at which the yield flow rates
change with respect to the changes in the
independent variable/parameter.
Property Base
row
Yield Fraction
Basis
Per Feed
Flowrate Option
With PIMSSubmodel
If you imported a PIMSsubmodel and selected the Use PIMSSubmodel
check box, on the Design tab |Model Data page, you can perform the
174
following tasks:
l
In the Model Source field, view the source destination for the
PIMSsubmodel.
View the Submodel Coefficients table, which shows the
SMCcoefficients in a representation of the PIMS spreadsheet.
Click the Edit Model Mapping button to access the PIMS to
RefSYSMapping Wizard.Refer to PIMS to RefSYSMapping Wizard for
further information.
In the Independent Parameters section, you can edit the Value for listed independent parameters, if desired.
Icon
Function
Lets you filter the list of variables in the table based on the
following types:
l
All
Real
Enumeration
Text
Code Only
Message
Create a New
User Variable
icon
Lets you create a new user variable and access the Create
a New User Variable property view.
Lets you sort the user variable list in ascending alphabetical order.
You can also open the edit property view of a user variable
by double-clicking on its name in the table.
175
Object
Icon
Function
Lets you sort the user variable list according to the order
by which they are executed by HYSYS.
Sorting by execution order is important if your user variables have order dependencies in their macro code.
Normally, you should try and avoid these types of dependencies.
Move Selected
Variable Up In
Execution Order
icon
Move Selected
Variable Down In
Execution Order
icon
Lets you move the selected user variable down in the execution order.
176
Distillation
1. From the Stream drop-down list, select the product stream associated
with the available curve data.
2. In the DistillationOptions section, select the Distillation radio button.
3. From the left-hand drop-down list, select the appropriate distillation
curve type.
Note: Alternately, you can use the Use Main Feed Distillation Curve check
box to apply that curve to the selected stream.
Light Ends
1. From the Stream drop-down list, select the product stream associated
with the available curve data.
2. In the DistillationOptions section, select the Light Ends radio button.
The Light Ends option lets you specify the desired light end composition.
3. From the Basis drop-down list, select the appropriate composition
basis.
4. Type a percentage value for each desired element in the table below.
Note: You can click the Reset button to reset all percentages to the default values.
177
Use the Utility Shift page to set up the output values and units for the utility
shift calculations.
If you specify the base and shift values for these utilities, the model will calculate the utility consumption and production based on the delta-base shift
concept.
Note: Before performing any actions on this page, you must add utility streams to the
reactor on the Design tab | Connections page.
To set up utilities:
l
Note: If a PIMS submodel consisting of calculated utilities (e.g. SDHT model) is loaded into
the PSR, the calculated utilities are automatically added to the utilities section, and are calculated by the EO solver. There is no need to manually specify base and shift values.
178
179
Note: Some PIMS properties may not exist in HYSYS Refining so they become
ignored. For the above example, the PIMS properties are: API, CON, and SUL.
The ve sign in PIMS means production. In HYSYS Refining, the +ve sign
means production. Take the values from the BAS column and multiple by
-1.
-999 represents 0
11. For the Property Base value, take the E Row values under the BAS
column.
12. Once all the base yields, shifted values, and property base values have
been added fill in the Cut point information. The Petroleum Shift Reactor
should have enough data to solve.
180
3. Select the Design tab | Model Data page and specify the model independent variables.
181
182
5. Specify the base yields for the products and the calculated feeds. For the
calculated feeds, the base yield will be negative as the flow is in the inlet
direction.
6. Specify the base and shift values for the model independent variables.
183
7. On the Product Specs tab | Product Cuts page, specify the Temperature, IBP, and FBP of the products and calculated feeds.
Note: Calculated feeds are treated almost as products in model calculations
except that (1) the flow is treated negative for material balance purpose, and (2)
properties cannot be shifted.
8. On the Product Specs tab | Assay Properties page, select the properties you want to shift. For the HydroDiesel stream, select Sulfur
Content and Liquid Density as the properties to be shifted. In this
model, the Hydrotreated Diesel is the main product stream and also the
only pseudo-component stream; as result, only its properties are desirable.
184
9. On the Product Specs tab | Property Shift page, specify the base and
shift values for the properties.
10. Specify the flowrate, temperature, pressure and composition for the
feed stream, that is, "DS1 feed" stream. Since some of the feed properties are model independent variables, make sure that the feed has all
the required properties (in this case, sulfur wt %, SG, and Cetane Idx).
If a property is missing, a trace warning message appears.
The models should solve at this point.
11. Select the Model Summary tab for a summary of the model inputs and
model results.
12. On the Model Summary tab | Inputs page, the feed flowrates and the
independent variables are reported. For the independent variables, the
values shown are the current values, as against those values shown on
the Model Data page that are their base values.
185
13. On the Results page, the product yields and product property values are
reported. These values are calculated using the delta-base shift values
specified on the Model Data page and Property Shift page.
186
9 Hydrocracker
HCR Environment
CalibrationEnvironment
ConfigurationOptions
Configuration Options
9 Hydrocracker
Stages
Reactors
Beds
Treating Beds
HPS
1-6
1-5
187
Configuration Options
Stages
Reactors
Beds
Treating Beds
HPS
1-12
1-11
2-12
1-11
1-2
3-18
1-17
1-2
Simulation
Major Simulation Inputs
l
188
Fresh feed and recycle feed compositions, based on the following inputs:
Gravity
Distillation
Sulfur content
Nitrogen content
Base feed lump composition used to supplement lab data given above
9 Hydrocracker
9 Hydrocracker
Global Activity
o
Reactor 1 - Bed 1
Reactor 1 - Bed 2
Reactor 2 - Bed 1
Reactor 2 - Bed 2
Treating bed
Treating bed
Treating bed
Treating bed
Treating bed
Treating bed
Treating bed
Treating bed
Treating bed
Treating bed
189
190
Treating bed
Treating bed
Treating bed
Treating bed
950+Cracking Activity
o
Treating bed
Treating bed
Treating bed
Treating bed
Treating bed
C1
C2
C3
C4
Catalyst Deactivation
o
Activation energy
WABT Bias
Reactor 1 - Bed 1
Reactor 1 - Bed 2
9 Hydrocracker
Reactor 2 - Bed 1
Reactor 2 - Bed 2
Calibration
Calibration requires all of the same inputs as simulation, except for the kinetic,
property, and miscellaneous coefficients highlighted above.These are calculated by the calibration case.In order to calculate these coefficients and
factors, the calibration requires some product data.
NH3 removal
9 Hydrocracker
191
Calibration Options
l
192
9 Hydrocracker
9 Hydrocracker
193
194
Group
Description
Kinetic Lumps
Lights
N2 NH3 H2S H2 C1 C2 C3 C4 C5
LP
Light Paraffins
MP
Medium Paraffins
C14P C18P
HP
Heavy Paraffins
C26P
VP
Vac. Paraffins
C47P
LN
Light Naphthenes
MN
Medium Naphthenes
HN
Heavy Naphthenes
VN
Vac. Naphthenes
LA
Light Aromatics
MA
Medium Aromatics
HA
Heavy Aromatics
VA
Vac. Aromatics
LS
Light Sulfur
MS
Medium Sulfur
HS
Heavy Sulfur
VS
Vac. Sulfur
VThA2N VThA3
LNi
Light Nitrogen
LBNit LNNit
MNi
Medium Nitrogen
HNi
Heavy Nitrogen
VNi
Vac. Nitrogen
VNNitA3 VBNitA2N
MNA
Medium Naph.
Aroms.
9 Hydrocracker
Group
Description
Kinetic Lumps
HNA
Heavy Naph.
Aroms
VNA
The Aspen HYSYS Hydrocracker model uses 97 kinetic lumps and 177 reactions.
9 Hydrocracker
Nitrogen
C9A*
MAN2HI*
HNNITA2*
IC9-2*
H2S
H2SC10A*
HN1*
HA4*
NC10*
Hydrogen
LTHA*
HA1*
C47P*
NC11*
Ammonia
MBNITN*
MTHA2*
VN1*
NC12*
Methane
MBNITA*
HN2*
VA1*
NC14*
195
Ethane
MTHN*
HN3*
VN2*
NC16*
Propane
MTHA*
HN4*
VN3*
C10N-1*
C4*
MS12*
MA2NHI*
VN4*
C10N-2*
C5*
MNNITA*
HAN*
VAN*
C12N*
C6P*
MN3LO*
MANAHI*
VBNITA2N*
C14N*
C6N*
MANLO*
HA2*
VA2*
C16N*
C6A*
MA2LO*
HAN2*
VTHA2N*
C12A*
C7P*
MAN2LO*
C26P*
VAN2*
C14A*
C7N*
C18P*
HAN3*
VAN3*
C16A*
C7A*
MA2NLO*
HA2N*
VA2N*
IC10*
LTH*
MN1HI*
HANA*
VANA*
IC11*
LBNIT*
MA1HI*
HA2N2*
VA2N2*
IC12*
C8P*
MANALO*
HA3*
VA3*
IC14*
C8N*
MN2HI*
HTHAN*
VA4*
IC16*
LNNIT*
MN3HI*
HBNITAN*
VNNITA3*
12N2*
C8A*
MANHI*
HS28*
VTHA3*
14N2*
C9N*
MTHAN*
HTHA2*
NC9*
16N2*
LS8*
MA2HI*
HBNITA2*
IC9-1*
Below is a legend to help you decode the meaning of the above list:
l
For components starting with C, the number beside the C indicates the
carbon number of the component. These components end in P, N, or A
indicating whether they are paraffins, naphthenes, or aromatics.
For components starting with IC, they are isoparaffins. The number
beside the C indicates the number of carbon atoms.
For components ending in N2, they are two ring naphthenic compounds.
The prefix number indicates the number of carbon atoms.
196
For components starting with NC, they are normal paraffins. The number
beside the C indicates the number of carbon atoms.
For these components with LO ending, they boil toward the beginning of
the distillate temperature range.
For these components with HI ending, they boil toward the end of the distillate temperature range.
9 Hydrocracker
For components starting with V, they boil in the vacuum resid range.
l
l
These components are either used directly in the kinetic reactor model or
mapped into the components used within the kinetic reactor model.
Aspen HYSYS Refining provides a transition command between the main flowsheet environment and the Hydrocracker subflowsheet environment to handle
the calculation of the composition of the Hydrocracker components. In order to
use the transition command, you must specify a feed type. The feed type will
specify a base composition of components in the kinetic reactor model basis.
This base fingerprint, along with the distillation, gravity, sulfur content, nitrogen and basic nitrogen content, and bromine number can be used to generate
the composition of the kinetic lumps used by the model.
In the Hydrocracker subflowsheet environment, you have more options for calculating the composition of the feed. For example, you can calculate the composition based on a boiling range of an assay by specifying bulk properties or
by specifying the kinetic lumps.
l
9 Hydrocracker
For the assay option, you can select an assay to be associated with the
feed. The feed type is specified along with the initial and final boiling
point to generate a composition of the feed.
For the bulk properties option, you can specify the feed type along with
distillation data, gravity, sulfur content, nitrogen and basic nitrogen content, and bromine number. You can optionally input data for refractive
index, viscosity, and Ca content.
For the kinetic lumps option, you can specify the feed type along with the
composition of the components that is desired. You can also enter a
bromine number to generate the inlet composition of olefins in the feed.
197
Reaction Kinetics
The Hydrocracker model is derived from a model developed by Sun Oil Company. The components and reaction networks are consistent with fundamental
research conducted at the University of Delaware, the University of Utah, and
other academic and industrial research institutions. This section provides
details of the reaction model.
The reactor model in the Hydrocracker model in Aspen HYSYS Refining is based
on rigorous kinetics. There are 97 components in the reaction network and 177
reaction pathways. The components and reaction networks are consistent with
typical Hydrocracking reactions.
Components
The component slate chosen to represent the feed and the product streams of
the Hydrocracker plant is comprised of 116 components covering the full range
from hydrogen to hydrocarbons with 47 carbon atoms (B.P. 1300 C).
In the reactor model, the 19 olefin components are assumed to be completely
saturated in the first reactor bed. These olefins are saturated in an Aspen extended reaction block before the kinetic model for the first reactor bed. The Aspen
extended reaction block calculates the enthalpy of reaction for the olefin saturation. This heat is distributed through the first reactor bed. This method
reduces the number of components throughout the reactor section in order to
improve the model performance.
l
The Component Slate for the Hydrocracker Reactor Model table shows
the corresponding components in the reactor model. The total number of
components in the reactor model is 97.
The Component Slate for Hydrocracker Model only in the feed table
shows the corresponding olefin components in the feed but not in the
reactor model.
The light ends will be defined using discrete components through C3. For C4 to
C10 hydrocarbons, one pure component is used to represents several isomers.
For example, the n-butane represents both n-butane and iso-butane. For higher
boiling point components, only compounds with carbon number 14, 18, 26, and
47 are used to represent a wide range of boiling point components.
The components also cover different classes of hydrocarbons that include onering naphthenics to 4-ring aromatics.
The 13 sulfur components are separated into 8 groups: thiophenes, sulfides,
benzothiophenes, tetrahydro-benzothiophenes, dibenzothiophenes, tetrahydrodibenzothiophenes, naphthabenzothiophenes, and tetrahydro-naphthabenzothiophenes.
The nitrogen compounds are represented by 10 components that include both
basic and non-basic nitrogen compound.
198
9 Hydrocracker
Formula
Abbreviation
Nitrogen
N2
N2
Ammonia
NH3
NH3
Hydrogen Sulfide
H2S
H2S
Hydrogen
H2
H2
Methane
CH4
C1
Ethane
C2H6
C2
Propane
C3H8
C3
N-Butane
C4H10_2
C4
N-pentane
C5H12_2
C5
2,3-dimethylbutane
C6H14_2
C6P
2,3-dimethylpentane
C7H16_5
C7P
2,3-dimethylhexane
C8H18_6
C8P
2,6-dimethylheptane
C9H20_4
C9P
2,5-dimethyloctane
C10H22-1
C10P
n-tetradecane
C14H30
C14P
n-octadecane
C18H38
C18P
Tetracosane
C26H54
C26P
C47 Paraffins
C47H96
C47P
Methylcyclopentane
C6H12-2
C6N
Methylcyclohexane
C7H14-6
C7N
Cyclohexane, 1,4dimethyl
C8H16-7
C8N
1-trans-3,5-
C9H18-1
C9N
C14-1-ring-cycloheaxane
C14H28
MN1Lo
C18-1-ring-cycloheaxane
C18H36
MN1Hi
C21-1-ring-cycloheaxane
C21H42
HN1
Class
Paraffins
CnH2n+2
Naphthenes
CnH2n
trimethylcyclohexane
9 Hydrocracker
199
Component
Formula
Abbreviation
C47-1-ring-cycloheaxane
C47H94
VN1
C10H18-2
C10N
C14-2-ring-cyclohexane
C14H26
MN2LO
C18-2-ring-cycloheaxane
C18H34
MN2HI
C21-2-ring-cycloheaxane
C21H40
HN2
C47-2-ring-cycloheaxane
C47H92
VN2
C14-3-ring-cyclohexane
C14H24
MN3Lo
C18-3-ring-cycloheaxane
C18H32
MN3Hi
C21-3-ring-cycloheaxane
C21H38
HN3
C47-3-ring-cycloheaxane
C47H92
VN3
C21-4-ring-cycloheaxane
C21H36
HN4
C47-4-ring-cycloheaxane
C47H88
VN4
Benzene
C6H6
C6A
Toluene
C7H8
C7A
Para Xylene
C8H10_3
C8A
2-methyl-3ethylbenzene
C8H12-3
C9A
1,2,3,4,-
C10H12
C10A
n-octylbenzene
C14H22
MA1Lo
C18-1ring-Arom
C18H30
MA1Hi
C21-1ring-Arom
C21H36
HA1
C47-1ring-Arom
C47H88
VA1
C14-
C14H20
MANLo
C18H28
MANHi
C21H34
HAN
Class
CnH2n-2
CnH2n-4
CnH2n-6
Aromatics
CnH2n-6
tetrahydronaphthalene
CnH2n-8
tetrahydronaphthalene
C18tetrahydronaphthalene
C21tetrahydronaphthalene
200
9 Hydrocracker
Component
Formula
Abbreviation
Class
C47-
C47H86
VAN
C14-naphthalene
C14H16
MA2Lo
C18-naphthalene
C18H24
MA2Hi
C21-naphthalene
C21H30
HA2
C47-naphthalene
C47H82
VA2
C14H18
MAN2Lo
C18H26
MAN2Hi
C21H32
HAN2
C47H32
VAN2
C14H14
MA2NLO
C18H22
MA2NHi
C21H28
HA2N
C47H80
VA2N
C21-3ring-Arom
C21H24
HA3
C47-3ring-Arom
C47H76
VA3
Fluorene, 9-methyl
C14H12
MANALo
CnH2n-16
C18H20
MANAHi
C21H26
HANA
C47H78
VANA
C21-4ring-Arom
C21H18
HA4
CnH2n-24
C47-4ring-Arom
C47H70
VA4
C21H30
HAN3
C47H82
VAN3
C21H24
HA2N2
C47H76
VA2N2
Thiophene
C4H4S
LTH
C8-Cyclo-sulfide
C8H16S
LS8
tetrahydronaphthalene
CnH2n-12
CnH2n-10
CnH2n-14
CnH2n-18
CnH2n-12
CnH2n-18
Sulfur Components
9 Hydrocracker
201
Component
Formula
Abbreviation
C12-Cyclo-sulfide
C12H24S
MS12
C28-Cyclo-sulfide
C28H56S
HS28
Benzothiophene
C8H6S
LTHA
Benzothiophene, dimethyl-
C10H10S
MTHA
C10-tetarhydro- benzothiophene
C10H12S
MTHN
C14-trtrahydro- dibenzothiophene
C14H16S
MTHAN
C21-trtrahydro- dibenzothiophene
C21H30S
HthAN
C14- dibenzothiophene
C14H12S
MthA2
C21- dibenzothiophene
C21H26S
HthA2
C47-tetrahydro-
C47H84S
VthA2N
C47H72S2
VTHA3
C4H9N
LBNit
C4H5N
LNNit
C9H11N
MBNITN
Quinoline (basic)
C9H7N
MBNITA
C9H9N
MNNitA
Phenanthridine, tetrahydro-
C21H33N
HBNitAN
Phenanthridine
C21H25N
MBNitA2
Carbazole, dimethyl-
C21H27N
MNNitA2
C35H55N
VBNitA2N
C47H73N
VNNitA3
Class
naphthabenzothiophene
C47-naphthabenzothiophene
Nitrogen Components
202
Formula
Abbreviation
C6H12
C6-olef
C7H14
C7-olef
C8H16
C8_OLEF
9 Hydrocracker
Component
Formula
Abbreviation
Cumene
C8H8
C8A_OLEF
C10H20
C10_OLEF
C10H16
C10N_OLE
C10H10
C10A_OLE
C14H28
C14_OLEF
C14H26
MN1Lo_OL
C14H20
MA1Lo_OL
C18H36
C18_OLEF
C18H34
MN1Hi_OL
C18H28
MA1Hi_OL
C21H40
HN1_OLEF
C21H34
HA1_OLEF
C26H52
C26_OLEF
C47H94
C47_OLEF
C47H92
VN1_OLEF
C47H86
VA1_OLEF
Reaction Paths
The Hydrocracker model in Aspen HYSYS Refining includes the following reaction types:
l
Hydrodesulfurization (HDS)
Hydrodenitrogenation (HDN)
Ring opening
Ring dealkylation
Paraffin hydrocracking
Saturation of olefins
9 Hydrocracker
203
204
9 Hydrocracker
9 Hydrocracker
205
206
Specify the WABT (weight average bed temperature) for each reactor
bed.
Specify the WART (weight average reactor temperature) for each
reactor and the temperature difference rise between each bed within
each reactor.
9 Hydrocracker
The nitrogen in the effluent from reactor 1 can be used instead of the WART for
reactor 1. Similarly, the conversion and bottoms flow can be used instead of
the WARTs for reactors 2 and 3.
Component Slate
The component slate chosen to represent the feed and the product streams of
the Hydrocracker plant comprises 116 components within the reactor section,
covering the full range from hydrogen to hydrocarbons, with 47 carbon components (B.P. 1300 C).
The component slate varies in different sub-plants. Component mappers are
used to connect adjacent sub-plants. Using different component slates helps to
reduce the number of variables in the sub-plant.
In the reactor model, the olefins components are assumed to be completely saturated. Table A below shows the corresponding components in the reactor
model. The total number of components in the reactor model is 97.
Table B below shows the corresponding olefin components in the feed but not in
the reactor model.
The light ends are defined using discrete components through C3. For C4 to C10
hydrocarbons, one pure component is used to represent several isomers. For
example, the n-butane represents both n-butane and iso-butane. For higher
boiling point components, only compounds with carbon number 14, 18, 26, and
47 are used to represent wide range of boiling point components.
The components also cover different classes of hydrocarbons, which include
one-ring naphthenes to 4-ring aromatics.
The sulfur compounds are separated into 8 groups of 13 components which
include:
l
thiophenes
sulfides
benzothiophenes
tetrahydro-benzothiophenes
dibenzothiophenes
tetrahydro-dibenzothiophenes
naphthabenzothiophenes
tetrahydro-naphthabenzothiophenes
The nitrogen compounds are represented by 10 lumps which include both basic
and non-basic nitrogen compounds.
Explanation of Abbreviations
l
9 Hydrocracker
207
region.
l
Light ends are either the formula or the carbon number for paraffins.
Most naphtha range components start with the carbon number and then
type (for C6 and above):
o
P = Paraffin
N = Naphthene
A = Aromatic
For M and higher components, Ax and Ny indicate the number of aromatic rings (x) and number of naphthenic rings (y). For example,
HA2N2 is a gasoil molecule with two aromatic rings and two naphthenic
rings.
For M and higher components, Th indicates a thiophene ring, BNit indicates a basic nitrogen ring, and NNit indicates a neutral nitrogen ring. For
example, VThA3 is a vacuum resid molecule with a thiophene ring and 3
aromatic rings.
Components toward the end of the list are just further breakdowns of
some of the distillate molecules:
IC molecules are isoparaffins.
o
o
C12N, C14N, and C16N are napthenes with 12, 14, and 16
total carbons.
Formula
Abbreviation
Nitrogen
N2
N2
Ammonia
NH3
NH3
Hydrogen Sulfide
H2S
H2S
Hydrogen
H2
H2
Methane
CH4
C1
Ethane
C2H6
C2
Propane
C3H8
C3
Class
Paraffins
208
CnH2n+2
9 Hydrocracker
Component
Formula
Abbreviation
N-Butane
C4H10_2
C4
N-pentane
C5H12_2
C5
2,3-dimethylbutane
C6H14_2
C6P
2,3-dimethylpentane
C7H16_5
C7P
2,3-dimethylhexane
C8H18_6
C8P
2,6-dimethylheptane
C9H20_4
C9P
2,5-dimethyloctane
C10H22-1
C10P
n-tetradecane
C14H30
C14P
n-octadecane
C18H38
C18P
Tetracosane
C26H54
C26P
C47 Paraffins
C47H96
C47P
Methylcyclopentane
C6H12-2
C6N
Methylcyclohexane
C7H14-6
C7N
Cyclohexane, 1,4-dimethyl
C8H16-7
C8N
1-trans-3,5-trimethylcyclohexane
C9H18-1
C9N
C14-1-ring-cycloheaxane
C14H28
MN1Lo
C18-1-ring-cycloheaxane
C18H36
MN1Hi
C21-1-ring-cycloheaxane
C21H42
HN1
C47-1-ring-cycloheaxane
C47H94
VN1
C10H18-2
C10N
C14-2-ring-cyclohexane
C14H26
MN2LO
C18-2-ring-cycloheaxane
C18H34
MN2HI
C21-2-ring-cycloheaxane
C21H40
HN2
C47-2-ring-cycloheaxane
C47H92
VN2
C14-3-ring-cyclohexane
C14H24
MN3Lo
C18-3-ring-cycloheaxane
C18H32
MN3Hi
Class
Naphthenes
9 Hydrocracker
CnH2n
CnH2n-2
CnH2n-4
209
Component
Formula
Abbreviation
C21-3-ring-cycloheaxane
C21H38
HN3
C47-3-ring-cycloheaxane
C47H92
VN3
C21-4-ring-cycloheaxane
C21H36
HN4
C47-4-ring-cycloheaxane
C47H88
VN4
Benzene
C6H6
C6A
Toluene
C7H8
C7A
Para Xylene
C8H10_3
C8A
2-methyl-3-ethylbenzene
C8H12-3
C9A
1,2,3,4,-tetrahydronaphthalene
C10H12
C10A
n-octylbenzene
C14H22
MA1Lo
C18-1ring-Arom
C18H30
MA1Hi
C21-1ring-Arom
C21H36
HA1
C47-1ring-Arom
C47H88
VA1
C14-tetrahydronaphthalene
C14H20
MANLo
C18-tetrahydronaphthalene
C18H28
MANHi
C21-tetrahydronaphthalene
C21H34
HAN
C47-tetrahydronaphthalene
C47H86
VAN
C14-naphthalene
C14H16
MA2Lo
C18-naphthalene
C18H24
MA2Hi
C21-naphthalene
C21H30
HA2
C47-naphthalene
C47H82
VA2
C14-1
C14H18
MAN2Lo
Class
CnH2n-6
Aromatics
CnH2n-6
CnH2n-8
CnH2n-12
CnH2n-10
ring-Arom-2-ring Naphthene
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9 Hydrocracker
Component
Formula
Abbreviation
C18-1
C18H26
MAN2Hi
C21H32
HAN2
C47H32
VAN2
C14H14
MA2NLO
C18H22
MA2NHi
C21H28
HA2N
C47H80
VA2N
C21-3ring-Arom
C21H24
HA3
C47-3ring-Arom
C47H76
VA3
Fluorene, 9-methyl
C14H12
MANALo
C18H20
MANAHi
C21H26
HANA
C47H78
VANA
C21-4ring-Arom
C21H18
HA4
C47-4ring-Arom
C47H70
VA4
C21-1
C21H30
HAN3
C47H82
VAN3
Class
ring-Arom-2-ring Naphthene
C21-1
ring-Arom-2-ring Naphthene
C47-1
ring-Arom-2-ring Naphthene
C14-2
CnH2n-14
ring-Arom-1-ring Naphthene
C18-2
ring-Arom-1-ring Naphthene
C21-2
ring-Arom-1-ring Naphthene
C47-2
ring-Arom-1-ring Naphthene
CnH2n-18
CnH2n-16
CnH2n-24
CnH2n-12
ring-Arom-3-ring Naphthene
C47-1
ring-Arom-3-ring Naphthene
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211
Component
Formula
Abbreviation
Class
C21-2
C21H24
HA2N2
CnH2n-18
C47H76
VA2N2
Thiophene
C4H4S
LTH
C8-Cyclo-sulfide
C8H16S
LS8
C12-Cyclo-sulfide
C12H24S
MS12
C28-Cyclo-sulfide
C28H56S
HS28
Benzothiophene
C8H6S
LTHA
Benzothiophene, dimethyl-
C10H10S
MTHA
C10-tetarhydro-benzothiophene
C10H12S
MTHN
C14-trtrahydro-dibenzothiophene
C14H16S
MTHAN
C21-trtrahydro-dibenzothiophene
C21H30S
HthAN
C14- dibenzothiophene
C14H12S
MthA2
C21- dibenzothiophene
C21H26S
HthA2
C47-tetrahydro-naphthabenzothiophene
C47H84S
VthA2N
C47-naphthabenzothiophene
C47H72S2
VTHA3
C4H9N
LBNit
C4H5N
LNNit
Quinoline,
C9H11N
MBNITN
C9H7N
MBNITA
C9H9N
MNNitA
ring-Arom-2-ring Naphthene
C47-2
ring-Arom-2-ring Naphthene
Sulfur Component
Nitrogen Component
1,2,3,4-tetrahydro- (non-basic)
Quinoline (basic)
212
9 Hydrocracker
Component
Formula
Abbreviation
Phenanthridine, tetrahydro-
C21H33N
HBNitAN
Phenanthridine
C21H25N
MBNitA2
Carbazole, dimethyl-
C21H27N
MNNitA2
C35H55N
VBNitA2N
C47H73N
VNNitA3
Class
Cumene
9 Hydrocracker
Formula
Abbreviation
C6H12
C6-olef
C7H14
C7-olef
C8H16
C8_OLEF
C8H8
C8A_OLEF
C10H20
C10_OLEF
C10H16
C10N_OLE
C10H10
C10A_OLE
C14H28
C14_OLEF
C14H26
MN1Lo_OL
C14H20
MA1Lo_OL
C18H36
C18_OLEF
C18H34
MN1Hi_OL
C18H28
MA1Hi_OL
C21H40
HN1_OLEF
C21H34
HA1_OLEF
C26H52
C26_OLEF
C47H94
C47_OLEF
C47H92
VN1_OLEF
C47H86
VA1_OLEF
Class
213
Kinetic Framework
In the Hydrocracker, each catalyst bed is modeled as a separate reactor. The
reaction mechanism is coded in Aspen Reactors, an open-equation modeling
platform in which kinetic constituents is segregated from hydraulic and heat balance relationships. This segregation permits different kinetic schemes to be
implemented within the same mechanical framework.
214
Activity
Description
SAT
HSAT
MSAT
LSAT
HDS
HHDS
MHDS
LHDS
HDN
HHDN
LHDN
PCR
HPCR
MPCR
LPCR
RDA
HRDA
MRDA
LRDA
9 Hydrocracker
d[LNNIT ]
dt
where:
(LNNIT] = Concentration of LNNIT
ACT = Total activity for the reaction. This is a product of each activity that
affects the reaction. In this case, the activities affecting the reaction are the
HDN and LHDN.
ADS
= LHHW Adsorption term
NIT
[H2] = Hydrogen concentration
n = Power for H2 for denitrogenation reactions. This value is unique for each
reaction type.
Adding a Hydrocracker
To add a Hydrocracker into a PFD:
1. Open an appropriate simulation case.
2. Press F12 to open the UnitOps property view.
3. In the Categories group, select the Refinery Ops radio button.
4. In the Available Unit Operations group, select Hydrocracker and click
Add.
The HCR Template Option property view appears.
5. In the HCR Template Option view, do one of the following:
o
Click Configure a New HCR Unit to add a Hydrocracker operation and configure it from scratch.
The HCR Configuration Wizard property view appears, and you
have to configure the basic structure of the Hydrocracker operation using the features available in the HCR Configuration Wizard. After you have specified the minimum information
required, the Hydrocracker operation appears on the PFD.
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215
2. In the first page of the HCR Configuration Wizard property view, configure the reactor in the Hydrocracker.
3. Click Next.
4. In the second page of the HCR Configuration Wizard property view, specify the parameters of the reactors in the Hydrocracker.
5. Click Next.
6. In the third and final page of the HCR Configuration Wizard property
view, select or specify a set of calibration factors.
7. Click Done.
HYSYS Refining completes the Hydrocracker subflowsheet, based on the
specified information from the HCR Configuration Wizard, and opens the
Hydrocracker subflowsheet environment.
8. In the HCR environment, you can:
o
Access and modify the fractionator by double-clicking the Fractionator icon in the Hydrocracker PDF.
Deleting a Hydrocracker
To delete an existing Hydrocracker operation, do one of the following:
l
216
On the PFD property view, select the Hydrocracker operation icon and
press DELETE.
9 Hydrocracker
l
l
Press F12 to open the UnitOps property view. From the Available Unit
Operations list, select Hydrocracker, and then click Add. On the HCR
Template Option dialog box, click Configure a New HCRUnit.
-or-
In the HCREnvironment, on the Hydrocracker ribbon tab |Hydrocracker Simulation group, click the ConfigurationWizard button.
-or-
On the HCR Reactor Section property view, select the Design tab |
Configuration page. Click the ConfigurationWizard button.
Configuration (1 of 3)
Geometry (2 of 3)
CalibrationFactors (3 of 3)
The following table lists the common buttons available at the bottom of the
HCR Configuration Wizard property view:
9 Hydrocracker
Button
Description
Next>
<Prev
Cancel
217
Button
Description
Close
Enables you to exit the HCR Configuration Wizard and keep any
specifications or changes made to the Hydrocracker operation.
Done
Enables you to exit the HCR Configuration Wizard and finish configuring the Hydrocracker operation.
Configuration (1 of 3)
In the first page of the HCR Configuration Wizard property view, you can
configure the basic design of the Hydrocracker.
You specify the number of reactors, number of beds per reactor, and number of
treating beds; based on this information, HYSYScalculates the number of cracking beds for the HCR.
Number of Cracking Beds = Total Number of Beds (Sum of Number of Beds per
Reactor) Number of Treating beds.
In a HCR model, all treating beds are placed before all cracking beds, since the
treating beds are usually aimed at preserving the catalyst in the later beds.
Supported
Not Supported
Single-Stage
or
Two-Stage
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9 Hydrocracker
Tip:If you select Two-Stage configuration option, you can also select the number of separators for the Hydrocracker using the Number of high pressure separators drop-down list. This drop-down list is not available for the Single-Stage
configuration option.
7. From the Naphtha Cuts drop-down list, select the number of naphtha
cuts in the fractionator.
8. From the Distillate Cuts drop-down list, select the number of distillate
cuts in the fractionator.
9. For a Single-Stage Hydrocracker that includes a Fractionator, you can
select the Recycle check box for the Bottom if you want to recycle the
bottom stream.
Note: For a Two-Stage Fractionator with a Fractionator, the Recycle check box
is automatically selected for the Bottom stream and cannot be cleared.
Geometry (2 of 3)
In the second page of the HCR Configuration Wizard property view, you can specify the parameters for the reactor beds in the Hydrocracker.
1. In the Internal Diameter column, specify the internal diameter of each
reactor bed.
2. In the Catalyst Loading column, specify the catalyst load of each
reactor bed.
3. In the Catalyst Density column, specify the density of the catalyst in
each reactor bed.
4. In the Bed Voidage column, specify the void fractions of the catalyst in
the each reactor bed.
5. Click the Next> button to access the Calibration Factors page.
Note:The number of Bed rows varies depending on how many reactor beds you select on
the Configuration page.
Calibration Factors (3 of 3)
The Calibration Factors page (third page) of the HCR Configuration Wizard
property view lets you either generate a set of calibration factors or select a set
from a list of any pre-saved calibration factor files.
To select an existing calibration factor set, click Option 2.
9 Hydrocracker
219
Tips:
l
Select the Ignore check box to ignore the Hydrocracker during simulation calculation of the process flow diagram. Clear the Ignore check box to restore the
Hydrocracker into the simulation calculation.
Connections
Calibration Factors
Notes
220
9 Hydrocracker
Click the Feed Type Library button to access the Feed Type
Library Property View and modify or configure the feed type
and data of a selected stream.
Note: You may want to assign a transition package to the product stream.
9 Hydrocracker
Global activity
HDS activity
HDN activity
SAT activity
Cracking activity
221
Catalyst deactivation
Feed
Specification
Catalyst Deactivation
Solver Options
Solver Console
EO Variables
Presolve Commands
Postsolve Commands
Note:The last column displays the total for each flow rate type.
222
9 Hydrocracker
Reactor Specifications
To specify the reactor options for the Hydrocracker:
1. On the PFD property view, double-click the Hydrocracker icon to open
the Hydrocracker property view.
2. On the Hydrocracker property view, click the Reactor Section tab and
select the Specification page.
3. In the Temperature group, specify the Inlet Temperature value for
each bed of each reactor in the appropriate cell.
The values in the Properties/Conversion table are calculated by HYSYS.
Temperature
Pressure
3. In the Product Heater table, specify the product temperature and pressure in the appropriate cells.
4. In the Hydrogen Makeup Stream table, specify the following parameters for each makeup stream of each loop:
o
Temperature
Pressure
Stream composition
9 Hydrocracker
223
Description
Convergence
Tolerance
group
Creep Step
Parameters
group
Completeness
Checking
group
224
9 Hydrocracker
9 Hydrocracker
Object
Description
SQP Hessian
Parameters
group
225
Object
Description
Line Search
Parameters
group
Step Control Iterations field. Enables you to specify the number of step iterations.
Do nothing
The EO solver report files for reactor models are written to the Temp directory.
226
9 Hydrocracker
2. In the Command field, enter the script command you want to run.
3. Click Run Command.
Tips:
l
To clear the commands in the Simulation Engine Message and Script Commands field, click the Clear Message button.
To retrieve previous command, click the Get Prev. Command button. The previous command appears in the Enter Script Command field.
To retrieve next command, click the Get Next Command button. The next command appears in the Enter Script Command field.
To clear the command in the Enter Script Command field, click the Clear Command button.
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
EO Variables
9 Hydrocracker
227
The grid on the Reactor Section tab | EO Variables page of the Hydrocracker lists all of the variables and their attributes. It may be used to change
the attributes of a variable. Whenever an attribute is changed, its background
color becomes yellow.
Use the table and the EO Variables button to inspect or edit the EO variables.
Right-click over the column headings to show or hide selected columns.
You can sort the variable list by any attribute in ascending and descending
order.
l
If any variable attributes have been changed, their Modified entry becomes
checked. To sort by Modified, double-click the Modified column header.
Zone Pressures
Specs
Note:If the Hydrocracker does not have a fractionator, this tab is blank.
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9 Hydrocracker
The Molar Feed Fraction column displays the feed fraction for each cut point.
The TBP 5% column displays the boiling point temperature at 5 percent of each
cut point.
The TBP 95% column displays the boiling point temperature at 95 percent of
each cut point.
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229
Feed Blend
Product Yields
Product Properties
Reactor
Hydrogen System
Fractionator
Hydrogen Balance
Volume percentage
Mass percentage
You can view the calculated standard cut or fractionated results by selecting the
appropriate radio button: Standard Cut Products and Fractionated
Products.
Note: The liquid product cuts for the Fractionated Products option correspond to those
specified on the Fractionator tab | Specs page.
230
9 Hydrocracker
9 Hydrocracker
231
1. On the PFD, double-click the Hydrocracker icon to open the Hydrocracker property view.
2. On the Hydrocracker property view, click the Results tab and select the
Fractionator page.
Bed 1
Bed 2
Sum
HCR Environment
The HCR (Hydrocracker) environment contains the individual objects and operations that make up the Hydrocracker operation.
You can specify detail information and configure the inner sections of the Hydrocracker.
Tip:To access the HCR environment, open the Hydrocracker property view and click the
HCR Environment button.
232
9 Hydrocracker
Tips:
o
Click the Ignored check box to ignore the reactor during simulation calculation of the process flow diagram. Clear the Ignored check box to
restore the reactor into the simulation calculation.
Configuration
Geometry
Notes
9 Hydrocracker
bed voidage
233
Note:Each row in the table represents a bed in the reactors. The number of rows depend
on the number of bed reactors in the Hydrocracker.
Library
Properties
Biases
5. In the table, modify the data properties based on the selected radio button.
Tips:
o
Click the Import button to import feed types into the current feed
stream. In the Available Feed Types property view, open the Look
in drop-down list and locate the folder containing the feed type file.
Select the feed type file (in *.csv) and click the Open button.
Click the Export button to export feed types from the current feed
stream. In the File selection for exporting Feed Types property
view, open the folder/location you want to save the feed type file (*.csv)
in using the Save in drop-down list. In the File name field, type the
name of the feed type file, and then click Save.
Click the Delete button to delete the feed type from the current feed
stream.
234
9 Hydrocracker
Notes:
o
The Feeds list displays the names of all the virtual and real streams connected to the reactor.
You can only add virtual type streams in the Properties page.
4. In the Feed Properties group, select the radio button to select one of
the following method to specify the feed stream properties:
o
Assay
Bulk Properties
Kinetic Lumps
Description
Feeds group
Displays both real and virtual feed streams connected to the Hydrocracker.
Add button
Delete button
Enables you to delete the selected feed stream from the Feeds group.
Enables you to specify bulk properties of the selected feed type in the
Feed Type list.
Kinetic
Lumps
radio button
Enables you to specify kinetic lumps properties of the selected feed type
in the Feed Type list.
Enables you to select the assay associated to the selected feed type in
the Feed Type list.
If the selected feed stream is a real stream, then both the internal and
external streams will be deleted.
This drop-down list is only available if you select the Assay radio button.
9 Hydrocracker
235
Object
Description
Contains a table that displays the list of properties available for you to
view or modify of the selected feed stream.
The variables available in this table vary depending on which radio button you select in the Selected Feed group.
236
Object
Description
Import button
Enables you to import feed types (from *.csv files) into the
Hydrocracker.
Export button
Delete button
Properties of Selected
Feed Type table
Lump Weight
Percents radio
button
9 Hydrocracker
In the Feed Type Library property view, you can select a feed type in the Feed
Types list and modify the selected feed type properties in the Properties of
Selected Feed Type table.
Tips:
l
Click the Import button to import feed types into the current feed stream. In the
Available Feed Types property view, open the Look in drop-down list and locate
the folder containing the feed type file. Select the feed type file (in *.csv) and click
the Open button.
Click the Export button to export feed types from the current feed stream. In the
File selection for exporting Feed Types property view, open the folder/location you want to save the feed type file (*.csv) in using the Save in dropdown list. In the File name field, type the name of the feed type file, and then
click Save.
Click the Delete button to delete feed type from the current feed stream.
Feeds
Specifications
Catalyst Deactivation
Solver Options
Solver Console
EO Variables
9 Hydrocracker
237
Note:The last column displays the total for each flow rate type.
Temperature
Pressure
4. In the Product Heater table, specify the product temperature and pressure in the appropriate cells.
5. In the Hydrogen Makeup Stream table, specify the following parameters
for each makeup stream of each loop:
o
Temperature
Pressure
Stream composition
6. In the Hydrogen Purge Fraction table, specify the purge fraction value
for each HPS loop.
238
9 Hydrocracker
Description
Convergence
Tolerance
group
Creep Step
Parameters
group
Completeness
Checking
group
9 Hydrocracker
239
240
Object
Description
SQP Hessian
Parameters
group
9 Hydrocracker
Object
Description
Line Search
Parameters
group
9 Hydrocracker
Step Control Iterations field. Enables you to specify the number of step iterations.
Do nothing
241
3. In the Enter Script Command field, enter the script command you
want to run.
4. Click Run Command.
Tips:
l
To clear the commands in the Simulation Engine Message and Script Commands field, click the Clear Message button.
To retrieve previous command, click the Get Prev. Command button. The previous command appears in the Enter Script Command field.
To retrieve next command, click the Get Next Command button. The next command appears in the Enter Script Command field.
To clear the command in the Enter Script Command field, click the Clear Command button.
EO Variables
This grid lists all of the variables and their attributes. It may be used to change
the attributes of a variable. Whenever an attribute is changed, its background
color becomes yellow.
You can sort the variable list by any attribute in ascending and descending
order.
l
If any variable attributes have been changed, their Modified entry becomes
checked. To sort by Modified, double-click the Modified column header.
Viewing Results
The Results tab enables you to view the calculated variable results on the
Hydrocracker Reactor Section view. The information is grouped into the following pages:
242
Feed Blend
Product Yields
Product Properties
9 Hydrocracker
Reactor
Hydrogen System
Hydrogen Balance
Extended Yields
9 Hydrocracker
243
Bed 1
Bed 2
Sum
244
9 Hydrocracker
Note: For multiple data sets, you can select the data set used for pre-calibration.
4. Click the Operation Measurement tab, and specify the measured data
for the reactor beds and heaters.
5. Click the Product Measurement tab, and specify the GC data of the
product streams in the GC Data page.
6. Click the Calibration Control tab, and specify the parameter and
objective function values for the calibrate run.
7. Click the Run Calibration button.
o
If you only have one data set, the Validation Wizard property
view appears.
On the Validation Wizard property view, validate the data set
and click the OK button to continue with the calibration run.
If you have more than one data set, the Select Data Sets for Calibration property view appears.
On the Select Data Sets for Calibration property view, select
and validate the data set you want, and click the Run Calibration button to continue with the calibration run.
8. After the calibration run has finish, click the Analysis tab to view the calibration run results.
Tips:
9 Hydrocracker
Click the Push Data to Simulation button to export the current calibration results to the Hydrocracker variables in the simulation case.
Click the Pull Data from Simulation button to import the Hydrocracker variable values, from the simulation case, into the Calibration
property view.
Click the Return to Simulation button to exit the Calibration environment and return to the Hydrocracker environment.
245
If the Total cell under the Mass Flow column (in the Feed Group)
equals the Total cell under the Measured Mass Flow column (in the
Product Group), the current data set is valid and is used in the calibration
run.
If the Total cell under the Mass Flow column (in the Feed Group) does
not equal the Total cell under the Measured Mass Flow column (in the
Product Group), you can assign a bias feature to manipulate/adjust the
mass flow rate of the product stream whose measured data are less reliable.
To assign the bias feature to a product stream, select the appropriate
check box under the Assign Bias column. Clear the check box to
remove the bias feature.
Thus the adjusted data set is valid and used in the calibration run.
In the Coke and Sulfur Balance group, you must specify the following values
for the Calibration of coke and sulfur balance:
l
The Validation Wizard view appears when one of the following occurs:
l
The Run Calibration button (in the Calibration property view) is clicked
and the Calibration property view only has one data set.
The check box under the Include column (in the Select Data Sets for Calibration property view) is selected.
Notes:
l
HYSYS always validates the selected data set before the calibration is actually run.
The coke mass flow and hydrogen in coke are also calculated from flue gas analysis.
Any unreasonable values indicate that the flue gas analysis is questionable and
you should not proceed with the calibration.
If the total product mass rate is greater than the total feed mass rate by about 23%, you should review the flow rate and gravity information of the products. If you
think the error is acceptable, you can decide how you would like to distribute the
mass imbalance by assigning the bias to any of the product streams (except coke).
Once the bias is assigned, the Validation Wizard adjusts the mass flow of the selected product stream(s) to match the feed total mass by re-normalization.
l
246
9 Hydrocracker
2. In the Select Data Sets for Calibration property view, select the
check box, under the Include column, associated to the data set you
want to use.
Each time the check box is selected, the Validation Wizard property view
appears.
3. In the Validation Wizard property view, validate the data set and click
OK.
Under the Status column, the status of the data set displays OK.
Note:If the data set is not ready for the calibration run (for example, the status
displays Input Incomplete), the check box beside the data set is inactive.
4. Repeat steps 2 and 3 till you have selected and validated all the data set
you want to include in the calibration run.
5. On the Select Data Sets for Calibration view, click the Run Calibration
button to begin the calibration run.
Note:The Run Calibration button is inactive until you select a data set for the calibration run.
Tips:
l
Click the Stop button to stop the calibration run during mid-calculation.
Click the Close button to exit the Select Data Sets for Calibration view.
9 Hydrocracker
247
You can edit the following variables in the Factor Set property view:
l
Name of the calibration factor set: Enter the name of the calibration
factor set in the Name field.
Description of the calibration factor set: Enter information about the calibration factor set in the Description field.
Reactor variables
Fractionator variables
Notes:
l
The Date Created and Date Modified fields display the date and time the calibration factor set was created and last modified.
If the Hydrocracker does not contain a fractionator, than the Fractionator page
appears blank.
Reactor Parameters
To edit the reactor parameters of a factor set:
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9 Hydrocracker
You can modify the name of the calibration factor set by entering the
new name in the Name field located in the Factor Set group.
You can modify the description of the calibration factor set by entering
the information in the Description field located in the Factor Set group.
Fractionator Parameters
To edit the reactor parameters of a factor set:
1. Open the Factor Set property view.
Notes:
o
Tips:
o
You can modify the name of the calibration factor set by entering the
new name in the Name field located in the Factor Set group.
You can modify the description of the calibration factor set by entering
the information in the Description field located in the Factor Set group.
9 Hydrocracker
249
From the Reactor Section view, from the reactor's ribbon tab,
click Select CalibrationFactors. On the Calibration Factor
Set dialog box, click the Library button.
-or-
250
Object
Description
Available Data
Sets list
Displays all the data sets available in the associate calibration/prediction run.
Add button
Delete button
Clone button
Rename button
Enables you to rename the selected data set in the Available Data Sets list.
9 Hydrocracker
9 Hydrocracker
251
The HCR Calibration view contains the following objects below the tabs:
Object
Description
Run CalEnables you to select one or more data set for the calibration run and
ibration But- access the Validation Wizard property view. This button is unavailable
ton
until all necessary input data is complete.
Run Prediction
button
Enables you to select one or more data set for the prediction run and
access the Specification Wizard property view. This button is unavailable
until all necessary input data is complete.
Data Set
Enables you to select different data sets for entering the data or viewing
the results for the calibration or the prediction run.
drop-down
list
252
Manage
Data Sets
button
Enables you to access the Data Set Manager property view to create,
copy, delete, and rename data sets.
Push Data
to Simulation button
Enables you to export input data from the current data set in the calibration property view to the property view in the HCR environment.
Pull Data
from Simulation button
Return to
Simulation
Enables you to exit the Calibration environment and return to the HCR
environment.
Status Bar
Any existing simulation data will be overwritten with the current calibration data.
Any existing calibration data will be over written with the current simulation data.
9 Hydrocracker
Hydrocracker Design
Reactor Configuration
The Configuration page on the Design tab of the Calibration property view
is a read-only page.
This page displays the flowsheet configuration information:
l
Note: To change configuration specifications, you must return to the HCR environment.
Description
Internal Diameter
Catalyst Loading
Catalyst Density
Bed Voidage
9 Hydrocracker
Field
Description
Total Length
Injection Point
253
Library
Properties
Note:Any modifications to the variables in this tab will only affect the calibration/prediction run calculation.
Description
Feed Types
Properties of
Selected Feed
Types
Biases
Import button
Lets you import a feed type from a file in the HCR operation.
Export button
Lets you export a selected feed type (from the Feed Types list) into a
separate file. The exported feed type can be imported into a different
HCR operation.
Delete button
Lets you delete a selected field type in the Feed Types list.
254
9 Hydrocracker
For example, you can change the cloned feed type name by entering the
new name in the Name field.
6. When you have completed the modifications, click the Close icon to exit
the Feed Type property view.
The cloned feed type appears in the Available Feed Types list of the
Library page.
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255
4. In the Selected Feed group, click the radio button to select one of the
following methods to specify the feed stream properties. The HCR model
uses these feed types and Feed Type properties to generate kinetic
lumps of the feed for the simulation.
o
Assay
Bulk Properties
Kinetic Lumps
If you selected the Assay radio button, the feed properties calculated from the assay and the cut points appear. The properties include the following:
Field
Description
Feed Type
The feed type. Select the feed type from the drop-down
list. The feed types available are those in the Feed
Types list on the Library page of the Feed Data tab.
Assay
Initial
Point
Final Point
[C]
API Gravity
Specific
Gravity
(60F/60F)
Distillation
Type
256
TBP
D86
D1160
D2887
0% Point
(C]
5% Point
(C]
10% Point
(C]
30% Point
(C]
9 Hydrocracker
Field
Description
50% Point
(C]
70% Point
(C]
90% Point
(C]
95% Point
(C]
100%
Point (C]
Total Nitrogen
(ppmwt]
Basic Nitrogen
(ppmwt]
Total/Basic
Nitrogen
Ration
Sulfur Content%
Description
Name
Feed Type
The feed type. Select the feed type from the drop-down
list. The feed types available are those in the Feed
Types list on the Library page of the Feed Data tab.
API Gravity
Specific
Gravity
(60F/60F)
Distillation
Type
9 Hydrocracker
TBP
D86
D1160
D2887
257
Field
Description
0% Point
(C]
5% Point
(C]
10% Point
(C]
30% Point
(C]
50% Point
(C]
70% Point
(C]
90% Point
(C]
95% Point
(C]
Total Nitrogen
(ppmwt]
Basic Nitrogen
(ppmwt]
Total/Basic
Nitrogen
Ratio
Sulfur Content%
Notes:
l
258
The Feeds list displays the names of all the virtual and real streams connected to the reactor.
You cannot change the properties of a stream connected to an external
stream. You can only change the name and feed type of that stream.
You can only add virtual type streams in the Properties page.
9 Hydrocracker
Tips:
l
Feeds
Specification
Catalyst Deactivation
Fractionator
Solver Options
Solver Console
Presolve Commands
Postsolve Commands
9 Hydrocracker
Volume Flow
Mass Flow
Temperature
Pressure
259
4. In the Total Feed table, you can modify the properties of the reactors,
including the following:
o
Note:The last row displays the total for each flow rate type.
Click the Normalize button to modify the specified split ratio values to sum up to
1.
Click the Cancel button to exit the Select Feed Location property view without saving/accepting any of the changes.
Select the Reactor 1 radio button to have the entire selected feed stream flow
into reactor 1 of the Hydrocracker.
Select the Reactor 2 radio button to have the entire selected feed stream flow
into reactor 2 of the Hydrocracker.
260
9 Hydrocracker
Conversion, wt%
Description
Product Heater
Hydrogen Makeup
Stream
stream temperature
stream pressure
duty
Lets you modify the following properties of the hydrogen makeup stream:
l
temperature
pressure
composition
9 Hydrocracker
261
In the Feed Information section, you can specify the following value:
o
Feed Temperature
In the Column Energy Information section, you can specify values for
the following:
o
Reboiler Duty
Steam Flow
Steam Pressure
Steam Temp.
Tolerance
Max Iterations
Note:If the Hydrocracker does not contain a fractionator, then this page is blank.
Description
Convergence
Tolerance
Contains the Residual field that lets you specify the maximum residual value allowed for the convergence calculation.
Iteration Limits
Contains two fields that enable you to control the iteration range for
the OOMF Solver performance:
Creep Step
Parameters
262
Maximum Iterations field lets you specify the maximum number of iterations.
Minimum Iterations field lets you specify the minimum number of iterations.
Contains three fields that enable you to configure the creep function
of the OOMF Solver:
l
Step Size field. Lets you specify the size of each creep step.
9 Hydrocracker
Object
Description
Completeness
Checking
Contains the Override Spec Group Completeness check box that lets
you toggle between:
l
The normal calculation behavior requires the spec groups be completed before solving.
SQP Hessian
Parameters
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263
Object
Description
Line Search
Parameters
Normal (default). A proprietary line search designed to balance robustness with efficiency.
Exact. A well-known exact penalty line search. It is too conservative for most practical problems.
Contains the On/Off Switch drop-down list that lets you select one of
the following options:
l
Do nothing.
Running Pre-Calibration
You can also click the Run Pre-Calibration button (accessed from the Hydrocracker ribbon tab) to run the calibration without setting the objective function. It is a useful method to run the calibration without changing the degrees of
freedom. If you select the Run Pre-Calibration option, the model initializes
based on the current factor set and operating conditions. For further details,
refer to Running Pre-Calibration for the Hydrocracker.
264
9 Hydrocracker
EO Solver Reports
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
3. In the Enter Script Command field, enter the script command you
want to run.
4. Click Run Command.
Tips:
o
To retrieve next command, click the Get Next Command button. The
next command appears in the Enter Script Command field.
To clear the command in the Enter Script Command field, click the
Clear Command button.
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265
Object
Description
Temperature Rise
Pressure Drop
Note: The number of columns depends on the number of reactors. The number of rows is
the maximum number of beds among all reactors. The filed will be locked as a blank if the
particular bed does not exist in the specific reactor.
For example, if there are three reactors and there are two beds in Reactor 1,
three beds in Reactor 2, and two beds in Reactor 3, then there will be rows for
Bed 1, Bed 2, and Bed 3. However, the cells for data in Bed 3 of Reactor 1 and
Reactor 3 will be blank and locked.
ProductMeas. Tab
Cuts Page: HCR Calibration
The Cuts page on the Product Measure tab of the Calibration property view
lets you specify the number of GC analyses and liquid product cuts.
The cuts available vary depending on whether the HCR has a fractionator.
If the HCR has a fractionator:
l
The naphtha cuts, LCO cuts and Bottom cuts are those you specified on
the HCR Configuration Wizard.
You must specify the number of liquid cuts, which correspond to the number of liquid product measurements you have.
Number/Options to Specify
Up to 5
Up to 4
Up to 3
Up to 2
Bottom cuts
266
Bottoms
9 Hydrocracker
Fuel Gases
LPGs
Naphthas
The table that appears in the Light Ends page lets you input measurement data
and is based on the number of fuel gas, LPC analyses and Napalm cuts specified
on the Cuts Page. For example, the Heavy Naphtha column appears only if
the configuration has a Heavy Naphtha draw.
For each type of cut (each cut is represented by a column) you can enter the
flow rate and composition in the appropriate cell.
Notes:
l
You only need to enter the Naphthenes, Olefins and Aromatics data for the naphtha cuts. The HCR model then extrapolates the curves to the regions where you
did not specify data.
For Fuel Gas columns, the Liquid Rate variable is not available. For the other
columns, the Gas Rate variable is not available.
When you enter a value for a composition, the Input Composition for GC Analysis dialog box appears, allowing you to enter the data.
The streams on the Heavy Liquids page correspond to the fractionated draws
that you specified:
l
The Olefins, Naphthenes and Aromatics in naphtha cut(s) are required input.
Those for other liquid cuts are optional.
The temperature and pressure are used for fractionator calibration.
Note: The Heavy Naphtha and Light Naphtha flows appear both on the Light Ends page
and on the Heavy Liquids page.
9 Hydrocracker
267
268
9 Hydrocracker
Product Properties
Reactor Page
Fractionator Page
Note:The calculated variable values in this tab are limited to the Calibration environment.
Calibration Summary
The Analysis tab | Calib Summary page of the Calibration property view displays the calculated calibration factors. You can save these Calibration Factors
as a named set that can then be used in calibration runs. You can also export
the calibration factors to a file.
Note:The calculated variable values in this page are limited to the calibration environment.
There are four buttons located on the top of the Calibration Factor page and two
groups. The following table outlines the buttons:
9 Hydrocracker
269
Button
Action
Save for
Simulation
Save and export the calibration factors for a simulation run, by clicking
Save for Simulation.
In the normal workflow, after running the calibration and reviewing the
results, you will save the calculated calibration factors. Therefore, if you
return to the Simulation environment, the system prompts you with
the following question:
Do you want to make the newly calculated calibration factors available
for simulation?
l
Export
Calibration
Factors
Library
Access the Calibration Set Library view and manage the calibration
factor sets.
Re-initialize
The Calibration Factors group displays all calculated reactor and (if it
exists) fractionator calibration factors:
Factors
Global Activity
Reactor 1- Bed 1
0.7000
Reactor 1- Bed 2
0.7000
Reactor 2- Bed 1
0.7000
Reactor 2- Bed 2
0.7000
9.761-e002
0.6336
270
Treating Bed
1.000
1.000
9 Hydrocracker
Factors
0.7581
1.000
1.000
1.000
0.2508
0.8342
1.217
1.000
1.665
1.000
7.000e-002
1.035
1.000
1.000
0.9032
1.000
9 Hydrocracker
271
Factors
Treating Bed
0.9182
1.000
0.1679
1.000e-002
2.200
1.000
2.498
1.000
0.8000
1.000
5.000e-003
1.000e-002
1.000
1.000
1.000
1.000
272
1.000
9 Hydrocracker
Factors
1.000
8.900
C2
5.000
C3
1.000
C4
0.1000
Catalyst Deactivation
Initial Deactivation Constant
Included
(Initial Value and Final Value will display if
present.
Included
Activation Energy
Included
Included
(Initial Value and Final Value will display if
present.
Included
(Initial Value and Final Value will display if
present.
Reactor 1- Bed 2
Included
(Initial Value and Final Value will display if
present.
Reactor 2- Bed 1
Included
(Initial Value and Final Value will display if
present.
Reactor 2- Bed 2
Included
(Initial Value and Final Value will display if
present.
9 Hydrocracker
273
Factors
Temperature Rise
RIBI Temperature Rise [C]
1.000
1.000
1.000
1.000
Recycle/Quench Throws
Reactor 1
Bed 1 [STD_m3/h]
720.0
Bed 2 [STD_m3/h]
720.0
Reactor 2
Bed 1 [STD_m3/h]
720.0
Bed 2 [STD_m3/h]
720.0
36.00
36.00
H2 Consumption
1.000
1.000
1.000
1.000
1.000
1.00
C3 Yield [%]
1.00
C4 Yield [%]
1.00
10.00
10.00
274
9 Hydrocracker
Section
Feed Group
Displays data on
l
Stream Name
Material Balance
Closures (Measured/Adjusted)
Product Group
Consumption
Chemical Hydrogen
9 Hydrocracker
275
The Product Properties group displays the following values for each of the
streams listed:
l
API Gravity
Specific Gravity
Sulfur [%]
Paraffins [%]
Naphthenes [%]
Aromatics [%]
RON
MON
Cetane Index
Watson K
276
9 Hydrocracker
Top Index
Bottom Index
Top R2
Bottom R2
The TBP Cut Points group displays the calculated cut point to match the specified flow rate of each zone.
9 Hydrocracker
Displays data on
l
Bed 1 [STD-m3/h]
Bed 2 [STD-m3/h]
Sum [STD-m3/h]
277
Group
H2 Balance
Displays data on
l
H2 Flow In
Hydrocracker References
1. "The Lower It Goes, The Tougher It Gets," Bradford L. Bjorklund, Neil
Howard, Timothy Heckel, David Lindsay, and Dave Piasecki, presented
at presented at the NPRA 2000 Annual Meeting, Paper No. AM-00-16,
March 26-28, 2000.
2. "Improve Refinery Margins and Produce Low-Sulfur Fuels," Scott W.
Shorey, David A. Lomas, and William H. Keesom, World Refining Special
Edition: Sulfur 2000, Summer 1999, p. 41.
278
9 Hydrocracker
10 FCC Reactor
Configuration Options
10 FCC Reactor
279
Configuration Options
Riser
Regenerator
Midpoint
Inj?
1-Stage
No
1-Stage
Yes
No
Yes
No
Yes
1-Stage
No
1-Stage
Yes
Simulation
Major Simulation Inputs
l
Gravity
Distillation
Sulfur content
Concarbon content
Base feed lump composition used to supplement lab data given above
280
10 FCC Reactor
and pressure
l
10 FCC Reactor
Metals Balance
281
Stripper Tuning
o
Stripper Parameter
Heat Balance
o
MAT Tuning
o
282
10 FCC Reactor
Coke yield as produced in the reactor system and burned in the regenerator
Calibration
Calibration requires all of the same inputs as simulation other than the kinetic,
property, and miscellaneous coefficients highlighted above.These are calculated by the calibration case.In order to calculate these coefficients and
factors, the calibration requires some product data.
10 FCC Reactor
Dense Bed T, Flue O2, Flue Co, Flue CO2 or Flue CO/CO2, CRC,
Air Rate (volume or mass), Enrich O2 (volume or mass), and
Cat Cooler Duty
Additionally, you must specify either Flue Gas T or Flue Gas Dense Bed
Delta T and Flue Gas SOx
283
284
API gravity
D2887, D1160, or TBP distillation (D86 is an option but is not recommended)
Refractive index and refractive index temperature (optional, but recommended)
Sulfur
Basic Nitrogen
10 FCC Reactor
instead)
l
Distillations are used to determine the mass of material in the boiling ranges
for the gasoline, light, heavy, and resid lumps. The distillation data are also
used to adjust the relative amount of one-ring, two-ring, and three-ring aromatic cores based on how the weight average boiling point changes for each of
the boiling ranges. The gravity, sulfur, viscosity, and refractive index are used
to determine the aromaticity of the feed. Estimation techniques are available
for feeds that are too dark for the measurement of the refractive index. Feed
carbon is used as a part of the coke calculation in the risers, reactor, and regenerator. Nitrogen and the metals are used to calculate catalyst activities.
There is a set of fingerprints included in the FCC feed type library. When a feed
such as VGO, hydrotreated VGO, resid, or other type of feed is used in the
model, it is necessary to select the appropriate fingerprint for the feed. If there
are multiple feeds, then the appropriate fingerprint for each feed should be
used. The feed characterization system then converts each feed to the 21 kinetic lumps and blends them together.
FCCKinetic Lumps
Riser conversion kinetics are derived from the Mobil ten-lump mechanism. The
FCC Reactor has expanded the number of reactant/product lumps to 21 and
changed the functionality of several key lumps. The reactions themselves are
all based on well-understood first order kinetics that all occur in the vapor
phase. The kinetic expressions are integrated along the length of the riser and
are dependent on the catalyst bulk density, coke on catalyst, MAT activity,
basic nitrogen, and metals content. The MAT activity and basic nitrogen are
entered from external model sources and affect the riser kinetics uniformly.
The catalyst bulk density and coke on catalyst are also integrated along the
riser length and are themselves a function of pressure drop, coke make, and
molar expansion. The pressure drop includes elements of head, friction, and
acceleration.
All kinetics in the reactor are based on the 21-lump kinetic system. The reaction pathways represent paraffinic cracking, naphthenic ring opening, alkyl side
chain cracking, ring condensation, kinetic coke make from typical condensation
reactions, and metals coke make due to dehydrogenation. The reaction paths
have been logically grouped to make yield parameterization more convenient.
Thus all the pathways which lead to gas make up one class, the gasoline pathways make up another class, and so on. In this way, with only a small number
of yield measurements off the operation unit, the kinetic rate parameters for
the more than fifty reaction pathways can be easily tuned to match the unit
yields. To match the specific product compositions that are observed on the unit
(provided that information is available), additional tuning of paraffinic and aromatic reaction rates must be performed.
10 FCC Reactor
285
This system divides the reactants and products into lumped aggregates of
material classified by chemical type and boiling point range. These lumps are
similar to pseudo-components but are based on molecular structure in addition
to the boiling range for typical pseudo-component breakdowns. The molecular
structures selected are based on likely reaction pathways and mechanisms
understood to exist in fluid catalytic cracking chemistry. The table below summarizes the lumps used in the model. These lumps are classified into paraffinic,
naphthenic and aromatic chemicals and each of these types is divided into four
boiling point ranges as shown in the table. Aromatics are further divided into
substituent carbons and ring aromatic carbons.
The components were also selected to represent convenient boiling ranges that
represent yields of light gases, gasoline, light cycle oil, heavy cycle oil, and the
main fractionator bottoms (which also include any remaining resid). The light
gas components represent all light gases from H2 to C5. The gasoline component represents the component range from C5 to 430 F.
There are three lumps that are not identified with a particular chemical type:
l
C lump: Used to calculate the light gases for methane through the
pentanes. This is based on a correlation using the C lump produced in the
kinetic paths and the composition of the feed.
Kcoke lump: Kinetic coke, the coke routinely produced through cyclization and condensation pathways.
Mcoke lump: Metals coke, the coke produced as a by-product of dehydrogenation reactions caused by the presence of active Ni equivalent on
the catalyst.
286
No.
Lump
NBP Range
Description
< 430 F
Gasoline Lump C5
Pl
430 650 F
Light Paraffins
Nl
Light Naphthenes
Ar1l
Ar2l
Asl
Ph
Nh
650-950 F
Heavy Paraffins
Heavy Naphthenes
10 FCC Reactor
No.
Lump
NBP Range
10
Ar1h
11
Ar2h
12
Ar3h
13
Ash
14
Rp
15
Rn
Resid Naphthenes
16
Ra1
17
Ra2
18
Ra3
19
Ras
20
Kcoke
21
Mcoke
> 950 F
N/A
Description
Resid Paraffins
Kinetic Coke
Metals Coke
The aromatic carbon classification helps to account for those carbons that can
be cracked into the gasoline range material and those that do not crack as easily. Ring carbons are those carbons that make up the aromatic structure and,
therefore, are less likely to crack into lighter material. Instead, they participate
in ring condensation reactions that eventually can lead to coke formation on the
catalyst. Substituent carbon atoms are the paraffinic substituent atoms on the
core aromatic structures. They include paraffinic carbon chains of varying
lengths and combinations that are distributed around the core aromatic structures.
The table above illustrates how the chemicals going into the FCCreactor model
are lumped. First, there is a division by boiling point. Then, there is a division
by chemical type:
l
Paraffinic
Naphthenic
Aromatic
The aromatics are further broken down into substituents and core, or ring carbons. Therefore, a chemical such as n-butylbenzene has 6 core C atoms and 4
substituent carbon atoms. Carbons in hydroaromatic structures, where a saturated ring is fused to an aromatic ring, are counted as substituent carbon
atoms. Tetrahydronaphthalene is an example of a hydroaromatic structure.
10 FCC Reactor
287
288
10 FCC Reactor
6. Propane
7. Iso-butane
8. Butenes
9. n-Butane
10. Iso-pentane
11. Pentenes
12. n-Pentane
10 FCC Reactor
289
Source Component
C4=
Iso-butene
1-Butene
Cis-2-butene
Trans-2-butene
1,3-butadiene
iC5
Iso-pentane
Cyclo-pentane
C5=
3-methyl-1-butene
1-Pentene
2-Methyl-1-butene
Cis-2-pentene
Trans-2-pentene
2-Methyl-2-butene
Cyclo-pentene
Isoprene (2-methyl-1,3-butadiene)
C6-430 G Lump
Benzene
C6-430 G Lump (no benzene)
FCCPARM_P1_act_coke_prod_act =
KCOKADJ_P1_ACT_COKE_PROD_ACT + (CF1 1)
290
10 FCC Reactor
The kinetic coke factor for a catalyst will be calculated by dividing the coke
yield obtained with the catalyst at standard conditions with a gas oil feed by the
coke yield obtained with a base catalyst at the same conditions. In equation
form:
()
()
CF1 n = CF1 b
Coke(n)
Coke(b)
Here, Coke(n) and Coke(b) are the coke yields obtained with the new and base
catalysts, respectively, in laboratory tests with a gas oil feed at standard conditions, adjusted to a constant conversion.
()
()
CF2 n = CF2 b
[LCO(b) / SO(b)]
[LCO(n) / SO(n)]
In this equation, the LCO and SO (slurry oil or bottoms) yields are based on the
laboratory yields obtained with each catalyst at standard conditions, adjusted
to a constant conversion.
MSA(b) 0.03 APR(n) 0.05
CF3n = CF3b
MSA(n)
APR(b)
10 FCC Reactor
291
In this equation, MSA is the matrix surface area and APR is the average pore
radius for the new (n) and the base (b) catalysts.
FCCPARM_P2_Act_Contam_Coke_Act =
MCOKADJ_P2_ACT_COKE_PROD_ACT + (CF4 1)
In order to calculate the metals coke factor for a new catalyst, it is necessary
to calculate the slope of the coke versus metals curve for both a base catalyst
and the new catalyst. This requires laboratory data both with and without
metals.
After adjusting the results to a constant conversion, the difference in coke
yields is divided by the metals level (Ni + V/2). The result is called MSLOPE.
CF4 is then calculated by the following equation:
()
()
CF4 n = CF4 b
MSLOPE(n)
MSLOPE(b)
Here, MSLOPE(n) and MSLOPE(b) are the slopes obtained with the new and base
catalysts, respectively.
GASMAP_WF_METHANE_TO_METHANE
= GASCF_BASE_SPLIT_FACTOR_1 CF5
GASMAP_WF_ETHYLENE_TO_ETHYLENE
= GASCF_BASE_SPLIT_FACTOR_1 CF6
GASMAP_WF_ETHANE_TO_ETHANE
= GASCF_BASE_SPLIT_FACTOR_1 CF7
GASMAP_WF_PROPYLEN_TO_PROPYLEN
= GASCF_BASE_SPLIT_FACTOR_1 CF8
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10 FCC Reactor
GASMAP_WF_PROPANE_TO_PROPANE
= GASCF_BASE_SPLIT_FACTOR_1 CF9
GASMAP_WF_ISOBUTAN_TO_ISOBUTAN
= GASCF_BASE_SPLIT_FACTOR_1 CF10
GASMAP_WF_BUTENES_TO_BUTENES
= GASCF_BASE_SPLIT_FACTOR_1 CF11
GASMAP_WF_NBUTANE_TO_NBUTANE
= GASCF_BASE_SPLIT_FACTOR_1 CF12
GASMAP_WF_ISOPENTA_TO_ISOPENTA
= GASCF_BASE_SPLIT_FACTOR_1 CF13
GASMAP_WF_PENTENES_TO_PENTENES
= GASCF_BASE_SPLIT_FACTOR_1 CF14
GASMAP_WF_NPENTANE_TO_NPENTANE
= GASCF_BASE_SPLIT_FACTOR_1 CF15
The individual component factors for a catalyst will be calculated by dividing
the component yield (in wt % of fresh feed) obtained with the catalyst at standard conditions with a gas oil feed by the component yield obtained with a base
catalyst at the same conditions. In equation form:
()
()
CFX n = CFX b
CY(n)
CY(b)
Here, CY(n) and CY(b) are the individual component yields obtained with the
new and the base catalyst, respectively, in laboratory tests with a gas oil feed
at standard conditions, adjusted to a constant conversion.
RISMAP_WF_BUTENES_TO_ISOBUTEN
= RISMCF_BASE_SPLITS_1_ISOBUTEN_CF16 CF16
10 FCC Reactor
293
RISMAP_WF_BUTENES_TO_1BUTENE
= RISMCF_BASE_SPLITS_2_1BUTENE_CF17 CF17
RISMAP_WF_BUTENES_TO_C2BUTENE
= RISMCF_BASE_SPLITS_3_C2BUTENE_CF18 CF18
RISMAP_WF_BUTENES_TO_BUTADIEN
= RISMCF_BASE_SPLITS_4_BUTADIEN_CF19 CF19
RISMAP_WF_ISOPENTA_TO_CYPENTAN
= RISMCF_BASE_SPLITS_5_CYPENTAN_CF20 CF20
RISMAP_WF_PENTENES_TO_3M1BUTEN
= RISMCF_BASE_SPLITS_6_3M1BUTEN_CF21 CF21
RISMAP_WF_PENTENES_TO_1PENTENE
= RISMCF_BASE_SPLITS_7_1PENTENE_CF22 CF22
RISMAP_WF_PENTENES_TO_2M1BUTEN
= RISMCF_BASE_SPLITS_8_2M1BUTEN_CF23 CF23
RISMAP_WF_PENTENES_TO_C2PENTEN
= RISMCF_BASE_SPLITS_9_C2PENTEN_CF24 CF24
RISMAP_WF_PENTENES_TO_T2PENTEN
= RISMCF_BASE_SPLITS_10_T2PENTEN_CF25 CF25
RISMAP_WF_PENTENES_TO_CYPENTEN
= RISMCF_BASE_SPLITS_11_CYPENTEN_CF26 CF26
RISMAP_WF_PENTENES_TO_ISOPRENE
= RISMCF_BASE_SPLITS_12_ISOPRENE_CF27 CF27
RISMAP_WF_G LMP_TO_BENZENE
= RISMCF_BASE_SPLITS_13_BENZENE_CF28 CF28
The individual split factors for a catalyst will be calculated as follows. For the
C4 olefin split factors, the yield of each individual olefin isomer is divided by
the total C4 olefin yield. The result is the weight fraction of that individual iso-
294
10 FCC Reactor
mer (WFI). The corresponding catalyst factor is then calculated by the following
equation:
()
()
CFX n = CFX b
WFI(n)
WFI(b)
Here, WFI(n) and WFI(b) are the weight fractions of each isomer obtained with
the new and the base catalyst, respectively, in laboratory tests with a gas oil
feed at standard conditions, adjusted to a constant conversion.
The same procedure outlined above for the C4 olefins is also used for the C5
olefins and the split of cyclo-pentane from iso-pentane.
The benzene split factor for a catalyst will be calculated by dividing the benzene
concentration in the gasoline obtained with the catalyst at standard conditions
with a gas oil feed by the benzene concentration in the gasoline obtained with a
base catalyst at the same conditions. In equation form:
()
()
CF28 n = CF28 b
BZC(n)
BZC(b)
Here, BZC(n) and BZC(b) are the benzene concentrations obtained with the new
and the base catalyst, respectively, in laboratory tests with a gas oil feed at
standard conditions, adjusted to a constant conversion.
()
()
CF29 n = CF29 b
HSLOPE(n)
HSLOPE(b)
Here, HSLOPE(n) and HSLOPE(b) are the slopes obtained with the new and base
catalysts, respectively.
10 FCC Reactor
295
will be different. CF30 accounts for these differences. In general, catalysts that
result in lower rates of hydrogen transfer reactions will have higher net endothermic heats of reactions. Such catalysts also tend to produce higher gasoline
octanes. A simple, but reliable, correlation exists between the net heat of reaction and the gasoline octane number produced by a catalyst in the laboratory.
For each octane number increase, the net endothermic heat of reaction
increases by 6.87 BTUs per pound of feed. CF30 will modify the term
FCCPARM_DH_Cracking in the model as follows:
BCR(n) 0.25
CF31n = CF31b +
1.0
BCR(b)
In this equation, BCR(n) and BCR(b) are the bottoms cracking ratios achieved
with the new catalyst and the base catalyst, respectively. These ratios are the
ratios of the yields of LCO to CSO (in volume percent of fresh feed) achieved at
a constant conversion, with a constant feed in the laboratory tests.
296
10 FCC Reactor
MAT_Fresh_Cat_MAT = CF32
CF32 will be calculated based on the conversion level achieved in the laboratory
testing after the mildest steam deactivation procedure, using the standard conditions and feed. In the Select Group Program, the mildest deactivation was performed at 1350 F for 24 hours, using 95% steam. It has been found that such
tests tend to magnify the differences relative to those that would be seen in
commercial plants. As a result, CF32 should be calculated as follows:
()
()
CF32 n = CF32 b +
[CONVM(n) CONVM(b)]
2
CONVM(n) and CONVM(b) are the conversion levels achieved after the mildest
deactivation severities with the new and the base catalysts, respectively.
MAT__Cat_deact_P5 = CF33
HT
is a function of MAT_Cat_deact_P5. CF33 will be calculated based on the
deact
differences in the deactivation constant that were observed in the laboratory
testing. To calculate a deactivation constant, it is necessary to obtain activity
data after two different deactivation severities. The deactivation constant is calculated using the following equation:
Ae =
(Af S)
(S + K)
For the purposes of calculating the deactivation constant (K), the kinetic fresh
activity (Af) is calculated using the MAT conversion after the mildest steam
deactivation severity. For this equation, kinetic activity is defined as follows:
A=
Conversion
(100 Conversion)
In all such equations, conversion may be in either wt% or vol% of fresh feed.
10 FCC Reactor
297
The kinetic equilibrium activity (Ae) is calculated using the conversion after the
more severe steam deactivation severity. A typical value of 0.01 is assumed
for 5, the fractional daily make up rate. After the deactivation constant is calculated for both the base and the new catalyst, CF33 is calculated as follows:
()
()
CF33 n = CF33 b
K(n)
K(b)
Am =
(Af S)
(S + Km)
For the purposes of calculating the metals deactivation constant (Km), the kinetic fresh activity (Af) is calculated using the MAT conversion after the mildest
steam deactivation severity (without metals). The kinetic activity with metals
(Am) is calculated using the conversion after metals deposition. A typical value
of 0.01 is assumed for 5, the fractional daily make up rate. After the metals
deactivation constant is calculated for both the base and the new catalyst, CF34
is calculated as follows:
()
()
CF34 n = CF34 b
Km(n)
Km(b)
Catalyst Factors 35, 36, 43, and 44: Light and Heavy
Gasoline Octanes
The gasoline octanes produced by a catalyst depend on a variety of catalyst
properties, including the rare earth level and the matrix activity. CF35 and
CF36 vary the RON and the MON of the gasoline, respectively, as follows:
298
10 FCC Reactor
CF35, CF36, CF43, and CF44 are based on the gasoline octanes measured in the
laboratory tests at standard conditions, adjusted to a constant conversion level.
These factors are calculated as follows:
Catalyst Factors 37, 38, 39, 45, 46, and 47: Gasoline Composition
The gasoline composition obtained with a catalyst depends on the same catalyst
properties that determine the gasoline octanes, mainly rare earth level and the
matrix activity. CF37, CF38, CF39, CF45, CF46, and CF47 vary the concentrations of light and heavy gasoline naphthenes, olefins and aromatics,
respectively, as follows:
10 FCC Reactor
299
300
10 FCC Reactor
CF61 through CF64 - Ron and Mon effects for ZSM-5: Refer to the rows
CF35-LNRON, CF36-LNMON, CF43-HNRON, and CF44-HNMON in
the ZSM-5 (STD) column of Complete Factors forZSM-5 for the relevant equations.
CF65 - Price
Complete sets of catalysts factors are provided to define the effects of changing
zeolite content, active matrix alumina content, zeolite rare earth content, and
for two different types of ZSM-5. Each of these sets of factors is described
below. These factors must be added or subtracted from the base catalyst
factors as appropriate.
10 FCC Reactor
301
Zeolite Content
As zeolite is added to a catalyst, it becomes more active, which either
increases the equilibrium MAT activity, or reduces the make-up rate required to
maintain activity. In addition, various yield selectivities are affected, and the
tolerance to vanadium improves. The factors define the effects of a 1.0 wt%
increase in zeolite content. Refer to Complete Factors for Zeolite Content, Alumina Content, and Zeolite Rare Earth Content for further details.
Alumina Content
As active matrix alumina is added to the catalyst, the main effect is to improve
the bottoms cracking activity. In addition, vanadium tolerance improves, while
nickel tolerance becomes slightly poorer. Certain catalyst selectivities are also
affected and gasoline octanes increase slightly. The factors define the effects of
a 1.0 wt% increase in active matrix alumina content. Refer to Complete Factors
for Zeolite Content, Alumina Content, and Zeolite Rare Earth Content for further
details.
302
10 FCC Reactor
Notes:
l
In order to calculate factors for a new catalyst, the following list of tests must
be obtained on both the new catalyst and on a catalyst for which factors are
already available (the base catalyst).
1. The fresh catalysts are equilibrated (deactivated) at a minimum of two,
and preferably, three different severities. The deactivation severity may
be increased by increasing time, temperature, steam partial pressure
and/or number of oxidation-reduction cycles. After each deactivation
severity, the catalyst is run in a micro-activity unit, an ACE unit or a circulating pilot plant (depending on the client's preference and budget)
using a standard gas oil feed at typical FCC operating conditions. These
tests generate a set of yield versus conversion curves that are used to
calculate the yields for the catalyst at a standard conversion level. The
yields obtained with the new catalyst relative to the yields obtained with
the base catalyst are the basis for many of the catalyst performance
factors in the database. The gasoline fractions from each test are analyzed for individual components via PIANO GC. Gasoline octanes are calculated from the gasoline composition data.
2. The fresh catalysts are loaded with standard levels of nickel and vanadium and are deactivated via a combination of steaming and cyclic deactivation (numerous oxidation/reduction cycles). The loaded and
deactivated samples are run in a micro-activity unit, an ACE unit, or a circulating pilot plant using the same gas oil feed as used for Step 1 above.
These results are used to calculate the metals effects on catalyst selectivities and deactivation rates.
3. The deactivated catalysts from Steps 1 and 2 are also tested with a
heavy feed, preferably one containing a significant amount of residual oil
(VTB). The standard resid feed used by Refining Process Services contains approximately 3.0 wt% Conradson Carbon Residue. Here again,
this testing can be performed in a micro-activity unit, an ACE unit, or a
circulating pilot plant. These results are used to calculate the catalyst
responses to changes in feed boiling range.
Note: These tests are recommended, but not required. The response of the catalyst to heavier feed components can also be predicted by the bottoms cracking
ratio achieved with the gas oil feed.
4. The following chemical and physical analyses are required on each catalyst:
10 FCC Reactor
303
21 point surface area (includes matrix surface area, zeolite surface pore size distribution, and pore volume)
Attrition Index
5. The analyses from Step 4 are used to calculate unit retention factors,
stripping efficiency factors and to determine certain catalyst selectivity
factors.
Many of the performance factors can be generated by the tests from Steps 1
and 4 only. If a refiner is not interested in running heavy oils and operates with
relatively low metals levels on the equilibrium catalyst, then the tests
described in Steps 2 and 3 are not critical and may be eliminated if cost is an
issue.
In general, the standard conditions are defined to maximize the accuracy of
the lab results. To obtain the best accuracy, the standard conditions are defined
to match the FCC data as closely as possible. For example, the lab feed would
be a sample of the same feed used at the FCC unit. Also, the reactor temperature would be the same as the FCC. For example, if the average FCC
reactor temperature was 1000 F, then the lab tests would be based at 1000 F.
The following table summarizes the ACE, MAT, or pilot plant tests required for
full factor development.
Note: Test 2 would probably be considered the standard conditions, since the catalyst has
been aged to Medium deactivation, which usually means the best estimate that matches
the FCC catalyst activity. The other data points would be the best matches to actual FCC
conditions.
Test Number
Deactivation Severity
Low
Medium
High
Medium
Medium
Medium
Feed Type
Gas Oil
Gas Oil
Gas Oil
Gas Oil
Resid
Resid
Cat/Oil Ratio
Base
Base
Base
Base
Base
Base
Reactor Temperature
Base
Base
Base
Base
Base
Base
Metals Level
Low
Low
Low
High
Low
High
The following tables list the complete factors for four different catalysts, along
with the factors for zeolite content, alumina content, zeolite rare earth content,
and for two types of ZSM-5.
304
10 FCC Reactor
Notes:
10 FCC Reactor
We recommend that you use the generic catalyst for your first catalyst. To simplify catalyst factor calculations, it is usually assumed that the base catalyst
factors are either 0 or 1. In this way, the current catalyst in the FCC is the base
catalyst, and all of its factors are 0 or 1. zero or one; then the factors for other catalysts are moved away from 0 or 1. Assuming 0 or 1 as shown in the generic catalyst is a good starting point. Later, if you want to study a change in catalyst, then
new catalyst factors will be moved from 0 or 1.
In the catalyst library that comes with the FCC model, the Conquest 95 catalyst
has factors set at 0 or 1, since this catalyst library is used to model hundreds of
catalysts across many different FCC units. Conquest 95 is assumed to be the base
for this library. However, you can make your own catalyst libraries with the current
catalyst as base or generic. Finally, some catalyst factors are not 0 or 1. These
factors represent physical data for the catalyst. This data should be set to match
the data for the catalyst.
Catalyst
CONQUEST95
NOVAD50G
RAMCAT45G
REDUXION60
1.000
0.789
0.883
0.869
1.000
1.083
1.050
1.079
1.000
1.004
1.021
1.039
1.000
1.205
0.779
1.111
CF5- C1
1.000
0.949
0.974
0.974
CF6- C2=
1.000
1.061
1.000
1.102
CF7- Ethane
1.000
1.000
0.951
0.927
CF8- C3=
1.000
1.051
1.086
1.150
CF9- Propane
1.000
0.963
0.778
0.877
CF10- IC4
1.000
1.092
0.978
1.122
CF11- C4=
1.000
1.185
1.240
1.172
CF12- NC4
1.000
0.910
0.730
0.809
CF13- IC5
1.000
1.092
0.978
1.122
CF14-Pentene
1.000
1.130
1.197
1.165
CF15- NC5
1.000
0.910
0.730
0.809
CF16- IC4=
1.000
0.965
0.991
0.975
CF17- 1C4=
1.000
1.012
1.003
1.009
CF18- c2C4=
1.000
1.011
1.002
1.007
CF19- C4diene
1.000
1.092
1.121
1.086
CF20- CyC5
1.000
1.004
1.005
1.004
305
306
Catalyst
CONQUEST95
NOVAD50G
RAMCAT45G
REDUXION60
CF21- 3M1B
1.000
0.878
1.174
1.04
CF22- 1C5=
1.000
1.097
0.864
0.961
CF23- 2M1B
1.000
0.878
1.174
1.04
CF24- c2C5=
1.000
1.088
0.851
0.957
CF25- t2C5=
1.000
1.101
0.847
0.957
CF26- CyC5=
1.000
1.002
1.004
1.001
CF27Isoprene
1.000
1.004
1.007
1.002
CF28- Bz
1.000
0.991
0.979
0.951
CF29- Met H2
1.000
1.205
0.779
1.111
CF30- Ht of Rx
0.000
+1.04
+1.29
+3.44
CF31-L Lump
0.000
-0.029
-0.031
-0.042
CF32-FR. MAT
80.14
79.19
77.09
73.24
CF33-DeactP5
0.500
1.737
1.730
1.674
CF34-MDEACT
0.500
1.021
0.857
0.567
CF35-LNRON
0.0
+0.3
+0.3
+0.8
CF36-LNMON
0.0
+0.15
+0.15
+0.5
CF37-LNNAP
0.0
-0.2
-0.3
-0.7
CF38-LNOLEF
0.0
+1.5
+1.5
+3.8
CF39-AROM
0.0
+0.3
+0.4
+0.8
CF40-LCO SPG
0.0
-0.0017
-0.0017
-0.0044
CF41-CSO
SPG
0.0
-0.0019
-0.0019
-0.0048
CF42-SOX
1.0
1.03
1.033
1.044
CF43-HNRON
0.0
+0.1
+0.1
+0.4
CF44-HNMON
0.0
+0.05
+0.05
+0.3
CF45-HNNAP
0.0
-0.4
-0.5
-0.7
CF46-HNOLEF
0.0
+0.3
+0.3
+1.3
CF47HNAROM
0.0
+0.7
+0.8
+1.1
10 FCC Reactor
Catalyst
CONQUEST95
NOVAD50G
RAMCAT45G
REDUXION60
CF48-LNSPGR
0.0
+0.0012
+0.0012
+0.0025
CF49-HNSPGR
0.0
+0.0009
+0.0009
+0.002
CF51-ZSA
141.7
213.0
137.0
257.6
CF52-MSA
183.3
69.3
101.4
106.4
CF53-ZE, W%
24.6
36.4
23.4
42.9
CF54-AL, W%
39.69
38.20
49.9
33.45
CF55ZRE,W%
11.89
7.61
5.73
1.84
CF56-Na,ppm
2100
3400
2500
3000
CF57-Ni, W%
0.0
0.0
0.0
0.0
CF58-V, W%
0.0
0.0
0.0
0.0
CF59-Cu, W%
0.0
0.0
0.0
0.0
CF60-Fe, W%
0.0
0.0
0.0
0.0
CAT TYPE
CONQUEST95
NOVA-D50G
RAMCAT-45G
REDUXION-60
DESC.
GASOLINE
GASOLINE
OCT-BBL
OCTANE
CF50-SPARE
10 FCC Reactor
Catalyst
Zeolite
Alumina
Rare Earth
-0.002
+0.0014
+0.0024
0.000
-0.005
+0.000
-0.0008
+0.0025
+0.000
-0.0016
+0.0021
-0.0212
CF5- C1
-0.0032
+0.0018
-0.0152
CF6- C2=
-0.0042
-0.0004
-0.0152
CF7- Ethane
-0.0040
-0.0004
-0.0152
CF8- C3=
-0.0036
+0.0023
-0.0222
CF9- Propane
-0.0012
+0.0002
-0.0125
307
308
Catalyst
Zeolite
Alumina
Rare Earth
CF10- IC4
-0.0013
+0.0019
-0.012
CF11- C4=
-0.0021
+0.0026
-0.0267
CF12- NC4
-0.0019
+0.0018
-0.0083
CF13- IC5
-0.0013
+0.0019
-0.012
CF14-Pentene
-0.0015
+0.0021
-0.0251
CF15- NC5
-0.0013
+0.0017
-0.0083
CF16- IC4=
-0.0010
+0.0024
-0.0099
CF17- 1C4=
+0.0003
-0.0008
+0.000
CF18- c2C4=
+0.0003
-0.0008
+0.000
CF19- C4diene
-0.001
+0.000
+0.000
CF20- CyC5
+0.000
+0.000
+0.000
CF21- 3M1B
-0.001
+0.0009
-0.0099
CF22- 1C5=
+0.000
+0.000
+0.000
CF23- 2M1B
-0.001
+0.0009
-0.0099
CF24- c2C5=
+0.000
+0.000
+0.000
CF25- t2C5=
+0.000
+0.000
+0.000
CF26- CyC5=
+0.000
+0.000
+0.000
CF27-Isoprene
+0.000
+0.000
+0.000
CF28- Bz
+0.0008
+0.0009
+0.0515
CF29- Met H2
-0.0016
+0.0021
-0.0212
CF30- Ht of Rx
-0.690
+0.315
-1.878
CF31-LCO/CSO
+0.0005
+0.0021
+0.005
CF32-FR. MAT
+0.379
+0.184
+0.754
CF33-HTDEAC
-0.001
-0.009
-0.0276
CF34-MDEACT
-0.016
-0.015
-0.0246
CF35-LNRON
-0.025
+0.06
-0.40
CF36-LNMON
-0.015
+0.04
-0.23
CF37-LNNAP
-0.01
-0.02
-0.04
10 FCC Reactor
Catalyst
Zeolite
Alumina
Rare Earth
CF38-LNOLEF
-0.15
+0.15
-0.40
CF39-LNAROM
+0.02
+0.04
+0.05
CF40-LCO SPG
+0.0002
-0.0002
+0.0005
CF41-CSO SPG
+0.0002
-0.0002
+0.0005
CF42-SOX
+0.0
-0.0032
-0.005
CF43-HNRON
-0.015
+0.04
-0.30
CF44-HNMON
-0.009
+0.03
-0.17
CF45-HNNAP
-0.01
-0.02
-0.03
CF46-HNOLEF
-0.08
+0.08
-0.30
CF47-HNAROM
+0.02
+0.07
+0.07
CF48-LNSPGR
-0.000084
+0.00012
-0.00023
CF49-HNSPGR
-0.000052
+0.00013
-0.0002
CF51-ZSA
+6.000
+0.000
+0.000
CF52-MSA
+0.000
+3.000
+0.000
CF53-ZE, W%
+1.000
+0.000
+0.000
CF54-AL, W%
+0.000
+1.000
+0.000
CF55-ZRE,W%
+0.000
+0.000
+1.000
CF56-NA, ppm
+100
+0.000
+0.000
CF57-Ni, W%
+0.000
+0.000
+0.000
CF58-V, W%
0.0
0.0
0.0
CF59-Cu, W%
0.0
0.0
0.0
CF60-Fe, W%
0.0
0.0
0.0
CAT TYPE
ZEOLITE
ALUMINA
RARE EARTH
CF50-SPARE
DESC.
10 FCC Reactor
309
310
Catalyst
ZSM-5
(STD)
ZSM-5
(HISEL)
ZSM-5 (STD)
HIGHACT
ZSM-5 (HISEL)
HIGHACT
CF1- Kin.
Coke
+0.000
+0.000
+0.000
+0.000
CF2- Fd.
Coke
+0.000
+0.000
+0.000
+0.000
CF3- Str.
Eff.
+0.000
+0.000
+0.000
+0.000
CF4- Met
Coke
+0.000
+0.000
+0.000
+0.000
CF5- C1
+0.0001
+0.000
+0.0001
+0.000
CF6- C2=
+0.0001
+0.000
+0.0001
+0.000
CF7Ethane
+0.0001
+0.000
+0.0001
+0.000
CF8- C3=
+0.110
+0.0672
+0.110
+0.0672
CF9- Propane
+0.017
+0.0107
+0.017
+0.0107
CF10- IC4
+0.030
+0.0207
+0.030
+0.0207
CF11C4=
+0.051
+0.0397
+0.051
+0.0397
CF12NC4
+0.001
+0.0004
+0.001
+0.0004
CF13- IC5
+0.014
+0.0102
+0.014
+0.0102
CF14Pentene
+0.028
+0.021
+0.028
+0.021
CF15NC5
+0.000
+0.0000
+0.000
+0.0000
CF16IC4=
+0.0041
+0.0060
+0.0041
+0.0060
CF171C4=
-0.0024
-0.0015
-0.0024
-0.0015
CF18c2C4=
-0.001
-0.0011
-0.001
-0.0011
CF19C4diene
+0.0002
+0.0001
+0.0002
+0.0001
10 FCC Reactor
10 FCC Reactor
Catalyst
ZSM-5
(STD)
ZSM-5
(HISEL)
ZSM-5 (STD)
HIGHACT
ZSM-5 (HISEL)
HIGHACT
CF20CyC5
+0.000
+0.000
+0.000
+0.000
CF213M1B
+0.0021
+0.0032
+0.0021
+0.0032
CF221C5=
-0.0023
-0.0031
-0.0023
-0.0031
CF232M1B
+0.0021
+0.0032
+0.0021
+0.0032
CF24c2C5=
-0.0005
-0.0010
-0.0005
-0.0010
CF25t2C5=
-0.0005
-0.0010
-0.0005
-0.0010
CF26CyC5=
+0.000
+0.000
+0.000
+0.000
CF27Isoprene
+0.000
+0.000
+0.000
+0.000
CF28- Bz
+0.012
+0.006
+0.012
+0.006
CF29- Met
H2
+0.000
+0.000
+0.000
+0.000
CF30- Ht
of Rx
+0.080
+0.050
+0.080
+0.050
CF31LCO/CSO
-0.003
-0.0016
-0.003
-0.0016
CF32-FR.
MAT
-0.300
-0.300
-0.150
-0.150
CF33HTDEAC
+0.000
+0.000
+0.000
+0.000
CF34MDEACT
+0.000
+0.000
+0.000
+0.000
CF35LNRON
+1.3*
[75/R]6
0.86*[75/R]
+1.3*[75/R]6
0.86*[75/R]6
CF36LNMON
+1.0*
[75/R]6
0.83*[75/R]
**6
+1.0*[75/R]6
0.83*[75/R]6
CF37LNNAP
+0.03
+0.02
+0.03
+0.02
311
Catalyst
ZSM-5
(STD)
ZSM-5
(HISEL)
ZSM-5 (STD)
HIGHACT
ZSM-5 (HISEL)
HIGHACT
CF38LNOLEF
+0.02
+0.01
+0.02
+0.01
CF39LNAROM
+0.30
+0.16
+0.30
+0.16
CF40-LCO
SPG
-0.00001
-0.00001
-0.00001
-0.00001
CF41-CSO
SPG
-0.00001
-0.00001
-0.00001
-0.00001
CF42-SOX
+0.0
+0.0
+0.0
+0.0
CF43HNRON
+1.0*
[75/R]**6
0.66*[75/R]
**6
+1.0*[75/R]**6
0.66*[75/R]**6
CF44HNMON
+0.8*
[75/R]**6
0.64*[75/R]
**6
+0.8*[75/R]**6
0.64*[75/R]**6
CF45HNNAP
+0.03
+0.02
+0.03
+0.02
CF46HNOLEF
+0.01
+0.01
+0.01
+0.01
CF47HNAROM
+0.35
+0.19
+0.35
+0.19
CF48LNSPGR
+0.00021
+0.00015
+0.00021
+0.00015
CF49HNSPGR
+0.0003
+0.00013
+0.0003
+0.00013
CF51-ZSA
+0.000
+0.000
+0.000
+0.000
CF52-MSA
+0.000
+0.000
+0.000
+0.000
CF53-ZE,
W%
+0.000
+0.000
+0.000
+0.000
CF54-AL,
W%
+0.000
+0.000
+0.000
+0.000
CF55ZRE,W%
+0.000
+0.000
+0.000
+0.000
CF56-NA,
ppm
+0.000
+0.000
+0.000
+0.000
CF50SPARE
312
10 FCC Reactor
Catalyst
ZSM-5
(STD)
ZSM-5
(HISEL)
ZSM-5 (STD)
HIGHACT
ZSM-5 (HISEL)
HIGHACT
CF57-Ni,
W%
+0.000
+0.000
+0.000
+0.000
CF58-V,
W%
0.0
0.0
0.0
0.0
CF59-Cu,
W%
0.0
0.0
0.0
0.0
CF60-Fe,
W%
0.0
0.0
0.0
0.0
CAT TYP
ZSM-5
(STD)
ZSM-5 (HI
SEL)
DESC.
Sulfur Distribution
In the FCC Reactor model, feed sulfur is distributed into standard and fractionated products based on reaction and fractionation models. The model contains methods for distributing the sulfur by boiling point. These distributions
permit the prediction of sulfur in the various products created by the GSP.
Sulfur entering the FCC Reactor unit is defined by the following for each fresh
feed:
l
The fresh feed rates and sulfur contents define the total rate of sulfur entering
the FCC Reactor. The individual fresh feed data is mass blended to produce blended values for the sulfur content and crackability factor.
The sulfur crackability factor defines the propensity of the sulfur to crack to
H2S or remain as compounds in heavy liquid products. This factor ranges from
zero to one. Zero will maximize cracking to H2S. One will minimize cracking to
H2S and force the sulfur to appear in the heavier liquid products. For example,
virgin gas oil will have a value of zero since most of its sulfur will crack to H2S.
On the other hand, a hydrotreated gas oil will have a value of one, since most
of the easily-crackable sulfur has been removed by the hydrotreater and the
remaining refractory sulfur will pass through the FCC Reactor and appear in
cycle oil cuts. The intent is to provide a factor that shows the difference
between alkyl sulfides and thiophenes in the feed. Sulfides tend to crack to H2S
while thiophenes remain in high molecular weight structures that concentrate in
the cycle oils.
In reaction models, sulfur is distributed into the following standard products:
10 FCC Reactor
313
H2S
C5 to 430 F naphtha
650+ F bottoms
Light naphtha
Heavy naphtha
LCO
HCO
Bottoms
The standard product sulfur content is distributed across a sulfur assay spanning over 100 real and pseudocomponents in the simple fractionation model.
With this sulfur assay, the individual product sulfurs are developed from stream
compositions flowing from the separation correlations in the fractionation
model. In this way, the product sulfurs show the impact of cutpoint and overlaps in the real products.
The standard FCC Reactor model is setup to represent five real products, as listed above. Even if some of these streams (for example, heavy naphtha or HCO)
do not exist for the current model, reasonable sulfur values must be entered for
these streams that make sense when compared to the existing streams: light
naphtha, LCO, and bottoms.
314
Kinetic coke
Metals coke
10 FCC Reactor
The Conradson carbon coke and non-vaporized coke are assumed to be physical
types of coke and are therefore deposited on the catalyst at the entrance of the
riser prior to any cracking or coking reactions.
Kinetic coke and metals coke are both determined from kinetic expressions and
are deposited on the catalyst gradually as reactions proceed through the riser
and reactor.
The stripper source coke is determined from the cat/oil ratio and stripper performance curves.
Kinetic Coke
Kinetic coke make is calculated by the following Arrhenius-type equation:
Rate(molfeed/hr/vol)=Af*Ai*exp(-Ea/RT)
Where, for kinetic coke:
Variable
Corresponds to
Af
Ai
Ea/R
Temperature in R
In Parameter cases, a parameter associated with the coke activities is determined from a set of test run data from the FCCReactor. This parameter is a linear multiplier on the kinetic coke rate.
The 21-lump reaction path schematic shows all of the paths that produce kinetic
coke. Each of these paths has associated with it an Arrhenius type rate expression.
Currently, not all of the paths that produce kinetic coke are used. The paths that
are in use reflect the conversion and involve the following lump types: Nl, Ar1l,
Ar2l, Asl, Ph, Nh, Ar1h, Ar2h, Ar3h, Ash, Ra1, Ra2, Ra3, Ras.
Metals Coke
Metals coke make is calculated by the following equation very similar to that
used for kinetic coke:
Rate(molfeed/hr/vol)=Af*Ai*exp(-Ea/RT)
Where:
10 FCC Reactor
315
Variable
Corresponds to
Af
Ai
Ea/R
Temperature in R
A parameter is adjusted in a calibration case to match test run data. It is a linear multiplier on the metals coke rate.
316
10 FCC Reactor
Conversion
Also, the stripper source coke has roughly the same composition as the reactor
effluent (50% of the hydrocarbon is highly valued gasoline).
Two key parameters can be used to tune the stripper model:
l
Typical values of performance slope are between 0.5 and 1. A typical value for
the percentage of coke generated from the stripper is 15%. The biggest handle
for tuning the stripper is the performance slope.
If you want the regenerator temperature to have a larger increase for an
increase in feed rate, increase the performance slope. However, do not
increase this slope to more than 4 or 5.
If the increase in regenerator temperature is still too small, you may again
increase the performance slope of the stripper and run another calibration
case. After a calibration case has been run, you may run another simulate case
with a 10% increase in feed rate to observe the regenerator temperature
response. It is recommended that the performance slope not be changed to a
value greater than 4 or 5. If the regenerator response is still not what is expected after the performance slope has been changed, you may change the percent
of total coke that comes from the stripper.
10 FCC Reactor
317
steam/ catalyst), at efficiencies less than 95% can be changed by setting the
slope for the performance and then re-running FCCReactor in parameter mode.
A typical value for the slope is 0.5 to 1.0. A higher value of slope will make the
stripper more sensitive to process changes. In other words, when the catalyst
circulation rate is increased, the incremental amount of coke produced will be
larger when the slope term is higher.
Calibration
Simulation
Calibration Mode
In calibration mode, the base composition curve of the effluent is constructed
by:
l
Each product property has a fixed reference curve. A property curve is a set of
property values versus the normal boiling point of the hypo-components. In calibration mode, this reference curve is adjusted to match the measured product
property to form the base property curve. The base property curve is then used
to calculate the property of the FCC standard cut products (that is, C5-430 F,
430 F-650 F, 650 F-950 F, 950 F+). The calculated property of the FCC standard
cut products is used to calibrate the product property correlation in the FCC
model.
Simulation Mode
In simulation mode, the base composition curve (obtained from the calibration
mode) is adjusted to match the composition of standard cuts (that is, C5-430 F,
430 F-650 F, 650 F-950 F, 950 F+) predicted by the kinetic model. The adjusted
base curve is then used to populate the composition of the assay in the FCC
effluent. Similarly, the base property curve (obtained from calibration mode) is
adjusted to match the property of standard cuts predicted by the model. The
adjusted base curve is then used to populate the property of the assay in the
FCC effluent.
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10 FCC Reactor
H2S is calculated by difference since feed, naphtha, cycle oil, and SOX
sulfur are specified.
The parameter case mass balance appears at the top of the Analysis | Mass
Balance sheet. Measured and adjusted mass flows appear for each product, as
well as the total flow and adjusted total flow of the product and the mass closure.
In the Calibration Environment, on the Product Meas | Light Ends page,
the light ends yields are entered once for the pure components using GLC
information. Similarly, the heavy ends yields (naphthas and cycle oils) on the
Product Meas | Heavy Liquids page.
10 FCC Reactor
H2S is calculated by difference since feed, naphtha, cycle oil, and SOX
319
The parameter case mass balance appears at the top of the Analysis | Mass
Balance sheet. Measured and adjusted mass flows appear for each product, as
well as the total flow and adjusted total flow of the product and the mass closure.
In the Calibration Environment, on the Product Meas | Light Ends page,
the light ends yields are entered once for the pure components using GLC
information. Similarly, the heavy ends yields (naphthas and cycle oils) on the
Product Meas | Heavy Liquids page.
Risers
Riser models consist of six key ingredients:
l
Riser configuration
Pressure drop
Hydraulics
Heat effects
The riser model is a segment of the fluidized riser that models the kinetics in
the riser and includes the geometry of the riser for hydraulic and volume
320
10 FCC Reactor
effects. It takes the hydrocarbon feed after the nozzle exit and combines it with
the regenerated catalyst to take the material to the reactor.
Two-phase pressure drops are calculated through the riser for both vertically
and horizontally configured risers. These orientations use different correlations
for hydraulic effects and pressure drop calculations. An angle of incline may
also be used for the horizontally oriented models. A pressure drop through the
riser is calculated from three different components: acceleration (kinetic
energy), frictional effects, and gravitational effects. Proper tracking of
hydraulic and pressure effects is necessary to model the changes in local bulk
density correctly. These changes interact with the kinetics along the riser.
The chemistry in the risers is endothermic and uses the heat generated in the
regenerator for the chemical transformations. This process is tracked along the
length of the riser and is manifested in the temperature profiles printed in the
detailed riser reports. In these profiles, the temperature of the hydrocarbon
catalyst mixture gradually drops from the entry zone to the riser exit into the
reactor. These temperature drops are used in the models to determine catalyst
flow rates. The net balance of the heat transfers is summarized in the cracking
parameter. This parameter is printed in custom reports for the risers. If all
properties and calculations were without error, the cracking parameter would
be zero. Generally, it is not zero, but a relatively small number less than about
10 to 20.
Coke laydown is differentially accounted for by the kinetics along the length of
the riser and the additional solids are transferred from the vapor phase to the
solid phase. These effects are manifested by the increase in the mass of flowing solids, decrease in the mass/moles of vapor and the changes in the properties of flowing catalyst and hydrocarbons. As coke builds up on the catalyst,
deactivation functions are used to lower the activity of the catalyst. A molar
heat of adsorption accounts for heat effects accompanying the coke laydown.
Its counterpart, the heat of desorption, is used in the regenerator where the
coke is burned. Coke is represented by a combination of H and C in the molar
ratio of to 1. This ratio can be changed in the model if desired.
Four types of riser configuration are supported:
l
Single riser
Dual riser
Reactor
The reactor model consists of three primary submodels. As the hydrocarbon
mixture enters the reactor vessel, a process of disengagement of the hydrocarbon and catalyst begins. Cyclone models are the final stage of this disengagement at the top of the reactor. Material entering the cyclone models
arrives there from the reactor free-board area. This area is represented by a
10 FCC Reactor
321
model that sends material, primarily catalyst, to the dense bed of the reactor.
From there the material enters the stripping zone where steam is used to
remove as much of the remaining hydrocarbons as possible from the catalyst
before it enters the spent catalyst transfer line.
Cyclone models use a parameterized, load-based calculation to entrain a fraction of the effluent hydrocarbon vapor with the catalyst. This entrained catalyst
is sent to the dense bed model. The fraction of the hydrocarbon not entrained is
sent to the overhead line of the reactor and to the delumper model. It ultimately goes to the MF as a set of defined chemicals and pseudocomponents.
The reactor dense bed model is a differential-algebraic model that models performs a single catalytic cracking reaction for the low concentration of hydrocarbons in the catalyst bed. It also performs a DP calculation across the height
of the bed. This height can be set using pressure measurements in the plant are
be specified directly in the model. In the latter case, the DP is calculated.
The outlet products of the reactor that proceeds to the stripping zone are the
catalyst and kinetic coke, and a portion of the entrained hydrocarbon vapor that
came down with the catalyst. Further cracking of the hydrocarbons occurs in
the dense bed and some of this material along with stripping steam proceeds to
the cyclone. There it mixes with the riser effluents that did not entrain with the
catalyst.
Heat balances are performed at each point of mixing in the above coupled system of cyclones, free board, and dense bed. These balances yield different temperatures at each point in the system:
l
Dense bed
The reactor dilute phase performs mass balance, heat balance, pressure drop
and reaction calculations. The dilute phase model represents the reaction
volume that exists between the outlet of the riser and the inlet to the reactor
cyclones.
Reactor dilute phase dimensions are murkier. Modern FCC units have a variety
of proprietary designs that attempt to reduce this residence time to near zero.
The dilute phase model assumes a simple cylindrical geometry with a diameter
and length set to arbitrary values to usually provide a low vapor residence
time, that is, less than one second. Further, the model contains a catalyst splitter to divert catalyst away from the dilute phase and straight to the catalyst
stripper model. Using the diameter, length, and catalyst split ratio, you can
approximate the performance of the reactor dilute phase section. A smaller
volume and high catalyst split ratio will minimize the impact of the dilute phase
section on model predictions.
322
10 FCC Reactor
Regenerator
Like the reactor, the regenerator consists of submodels, in this case the regenerator dense bed, the freeboard (disperse phase), and the cyclones. Each of
these submodels performs heat balance, material balance and pressure drop
calculations.
The regenerator dense bed models a bubbling bed with heterogeneous coke
burn and heterogeneous and homogeneous CO to CO2 burn. At the inlet, the following are processed:
l
Spent catalyst
Lift air
Combustion gas
10 FCC Reactor
323
FCCNozzle System
The nozzle system mixes feed with the hot catalyst and removes heat from the
catalyst to heat and vaporize the feed. In the 21-lump model, this process is
complicated by the process of converting from the detailed component list to
the 21-lump components used in the R/R system. All flashes are based on the
detailed component list. Once the transfer of energy from the catalyst to the
full feed is determined, the final temperature is applied to the 21-lump composition to determine the equivalent enthalpy for this compacted component
set.
properties for feeds, recycles, products, fresh catalyst, and makeup catalyst
Test runs are the preferred source of data although routine operating data, if it
has sufficient information, can be quite useful to tune the model as well.
Feed Blending
The FCC units modeled to date typically have several distinct feed classes
including virgin gasoils, resid, imported gasoils, FCC cycle oils, hydrocracker
gasoils, and coker gasoils. Projects have been implemented with and without
feed blending being included as part of the model.
Feed composition changes are taken into account using the feed bulk inspection
properties described below. The total feed to the unit may be characterized in
this way to generate the reactive component lumps used in model. However, to
324
10 FCC Reactor
model the FCC unit feed selectivity most accurately, adjust individual feed
blend components to match the most recently available bulk property inspections (list given in the table below). Then, blend the resulting lump compositions together to create a composite feed. Since the adjustment of the
individual feeds results in the creation of detailed lump compositions for each
individual feed, the blended lump composition is more accurate. When blending
feeds, the blended bulk properties do not provide sufficient information to fully
characterize the feed in detail.
API gravity
D2887, D1160, or TBP distillation (D86 is an option but is not recommended)
Refractive index and refractive index temperature (optional, but recommended)
Sulfur
Basic Nitrogen
10 FCC Reactor
API Gravity
325
Cloud Point
Pour Point
Sulfur/Nitrogen
Viscosity
O2 Injection Rate
Riser/Reactor
l
326
MAT
Surface Area
Bulk Density
Heat Capacity
ZSM-5 Content
10 FCC Reactor
Risers
Reactor
Stripper
Regenerator
Cyclones
From the Reactor Section view, from the reactor's ribbon tab,
click Select CalibrationFactors. On the Calibration Factor
Set dialog box, click the Library button.
-or-
Adding FCCs
When you add an FCC, you can:
l
10 FCC Reactor
327
1. Press F12.
2. On the UnitOps property view, select the Refinery Ops option.
3. From the Available Unit Operations list, click Fluid Catalytic Cracking.
4. Click Add.
The FCC Template Option property view appears.
5. On the FCC Template Option property view, do one of the following:
o
Configuring FCCs
You configure FCCs using the Configuration Wizard.
l
328
10 FCC Reactor
10 FCC Reactor
The Results tab of the FCC property view displays a wide variety of FCC
simulation results.
329
The information presented here is identical to that presented on the Results tab of the FCC Reactor Section property view. If a fractionator is
included, it also contains the summary of the fractionator performance.
l
The Analysis tab of the Calibration property view is populated with the
results of a calibration run. A calibration run fits the models kinetic rate
constants and base operating data to match an observed process operation, feed properties, and product yields. This is also called a tuning
run.
FCC Ready
In order to ensure that FCC calculations are accurate, the associated Component List must contain a prerequisite set of components. There are three
ways that you can add these components to the list:
l
Create a new component list and import the following RefSYS Component List: FCC Components Fahrenheit.cml.
330
Nitrogen
CO
Oxygen
CO2
H2S
10 FCC Reactor
Hydrogen
Methane
Ethylene
Ethane
Propane
Propene
n-Butane
i-Butane
i-Butene
1-Butene
13-Butadiene
tr2-Butene
cis2-Butene
2M-1-butene
3M-1-butene
2M-2-butene
2M-13-C4==
n-Pentane
i-Pentane
1-Pentene
tr2-Pentene
cis2-Pentene
Cyclopentane
Cyclopentene
H2O
10 FCC Reactor
331
FCC Configuration Wizard - Page 1 - Basic riser, regenerator, and fractionator configuration
2. Optionally, to allow midpoint injection, select the Allow Midpoint Injection check box.
3. In the Regenerator group, specify whether the Regenerator is:
o
Note: The above options are only available if you did not select Two Risers in the
Riser group.
332
10 FCC Reactor
In this
field
Enter
Naphtha
Cuts
Naphtha
Light
Naphtha
Heavy
Naphtha
Light
Naphtha
Medium
Naphtha
Heavy
Naphtha
LCO
Light LCO
Heavy
LCO
Bottoms
Bottoms
HCO
Bottoms
Naphtha
Cuts
Naphtha
Cuts
LCO Cuts
LCO Cuts
Bottom
Cuts
Bottom
Cuts
When you have finished specifying cut information, you can select the Recycle
check boxes to indicate which cuts are recycled.
The availability of a cut for recycling is dependent on the information you specify in the cuts section as shown in the following table:
10 FCC Reactor
in this field
Naphtha
Naphtha Cuts
Light Naphtha
2 or 3
Naphtha Cuts
Medium Naphtha
Naphtha Cuts
Heavy Naphtha
2 or 3
Naphtha Cuts
LCO
LCO Cuts
Light LCO
LCO Cuts
Heavy LCO
LCO Cuts
333
in this field
HCO
Bottoms Cuts
Bottoms
Bottoms Cuts
When these are complete, click Next to move to the Geometry section of the
wizard.
Risers
Strippers
Regenerators
Depending on the configuration you select, the options that appear in the Geometry page vary.
For the Riser group, there are two rows as described below:
Row
Description
Total Length
Diameter
If you specified two risers, the Riser group will also contain two columns
enabling you to enter a value for each of the above variables for each riser.
If mid-point injection is allowed, the Riser group contains the following rows:
Row
Description
Total Length
The average inner diameter of the top section riser (from injection
point to riser top).
Bottom Section
Diameter
The average inner diameter of the bottom section riser (from riser
bottom to injection point).
Injection Point
Use the average inner diameter for the riser diameter input. In the case with
midpoint injection, the injection point is measured from the bottom of the riser.
The length and diameter of the riser termination zone is dependent upon the
desired residence time of the vapors leaving the tip of the riser and the entry of
the secondary reactor cyclones. You could enter the actual diameter of the
334
10 FCC Reactor
reactor for the diameter field, and vary the length until the residence time
matches acceptable results.
For the Riser Termination Zone group, the options available do not change
with the configuration. The following two fields are available:
Field
Description
Length
Diameter
For the Stripper group, the options available do not change with the configuration. The following three fields are available:
Field
Description
Height
Diameter
Annulus Diameter
Description
Interface Diameter
The diameter interface between the dense bed and the dilute
phase.
The height of the Regenerators Cyclone inlet above the regenerator bottom.
10 FCC Reactor
335
The regenerator bed height is adjusted to get the correct cat inventory number
in the regenerator. The interfacial diameter is normally set equal to the regenerator bed diameter. Set the height of the inlet of the regenerator cyclone equal
to the length from the first stage cyclone inlet to the air grid. The equipment layout is based on the typical side-by-side FCCU design.
When all of the required fields are completed, click Next to proceed to the
Heat Loss page.
The possible heat loss pages for the various configurations are shown below:
Description
336
Field
Description
10 FCC Reactor
Description
When you are finished, click Next to proceed to the Calibration Factors
page.
If you click Option 2, you can choose from a saved Library file from a
previous design. There is a Default set available that you can save and
edit to your own design. Click Library... to access the editing functions
for the default calibration factors set.
When you are finished, click Done. The reactor is added to the flowsheet.
10 FCC Reactor
337
from
by
Configuration Wizard
the main
menu bar
Calibration property
view
the main
menu bar
the PFD
the PFD
number of risers
regenerator type
number of cuts
Calibration relates to the entire FCC because you can enter data measured from the fractionator products.
The Results Summary includes fractionated yields that are reported by
neither the reactor section nor the fractionator.
The FCC property view applies to the FCC in the flowsheet environment (not
the FCC environment). You access FCC property view from the top level flowsheet by right-clicking the FCC icon, and then clicking View Properties.
338
10 FCC Reactor
Utility
Streams
to specify
Riser Feeds
Risers
Reactors
Regenerators
Fractionators
10 FCC Reactor
339
Regenerator BFW
If the FCC has a fractionator, use the Connections page to specify which of the
fractionator streams are Side Stripper Steam Streams.
Fractionated Products
If the FCC has a fractionator, the Fractionated Products group displays:
l
Description
Weight Frac- The weight fraction of this catalyst in the base catalyst blend.
tion row
340
Zeolite row
Alumina
row
Rare Earth
row
10 FCC Reactor
Object
Description
Normalized
Total
column
Displays the sum of the Weight Fraction values and the blended values
for Zeolite, Alumina, and Rare Earth.
Catalyst
Library button
Normalize
button
Enables you to normalize the weight fraction of the base catalyst blend.
Blend
Details button
Enables you to access the FCC Catalyst: Catalyst Blend View of the selected catalyst in the Base Catalyst Blend and Composition table.
Export
Blend button
Enables you to export the active catalyst blend into a *.csv file.
The Catalyst Libraries view enables you to manage the catalyst blend
and select catalysts to include in the base catalyst blend.
If you have more than one catalyst in the base catalyst blend, you must
specify the weight fraction of each catalyst in the blend.
The default values of Zeolite, Alumina, and Rare Earth are displayed in
red when you add the catalyst to the blend. You can overwrite these values. The Base Catalyst Blend is always calculated using the normalized
weight fraction of the catalysts.
You can specify details about the ZSM-5 Additive in the ZSM-5 Additive group.
This group contains two fields, which are described below:
Field
Description
Selectivity
Standard (default)
High
10 FCC Reactor
Field
Description
341
Delete Catalysts
342
10 FCC Reactor
Calibration Factors
Use the Calibration Factors page on the Design tab of the FCC property view
to:
l
l
Reactor
To see what key Calibration Factors are displayed for the Reactor, click here.
To see what key Calibration Factors are displayed for the Fractionator, click
here.
From the Calibration Factors page, you can also access Calibration Set
Library.
Click Calibration Factors Library to:
l
The number of Calibration Factors is the same for all configurations, but not all
factors are applicable for all configurations. If no fractionator is present, then
all factors relating to the fractionator stay at their defaults. However, the group
of factors relating to the reactor section is always applicable.
10 FCC Reactor
343
When you import a set of Calibration Factors from a *.csv file, HYSYS checks
to ensure the configuration in the file matches the configuration in the current
case. If not, HYSYS constructs a warning such as the following:
Warning: The configuration used to produce this Calibration
Factor set (<setname>) does not match your current configuration.
The Reactor Section table contains the following calibration factors:
Calibration Factor
Description
Stripper parameter
344
Description
10 FCC Reactor
Reactor Factors
Advanced Factors
Fractionator Factors
Delumping Factors
9. When you have finished entering Calibration Factors, close the Factor
Set property view; then close the Calibration Set Library dialog.
The imported Calibration Factor set is now added to the Calibration Set
Library.
10 FCC Reactor
345
The Available Feed Types list shows the Feed Types associated with this
FCC.
Use the Library page to:
l
Assay
Bulk Properties
Kinetic Lumps
The FCC model uses these feed properties and the specified Feed Type to generate kinetic lumps of the feed for the simulation.
When you select a feed in the list box, the rest of the form is filled out with the
data for the selected feed. If the feed is a real stream, then you cannot choose
a property method. You can change only the feed name and the feed type.
If you clone a riser feed which is mapped to an external stream, HYSYS copies
the calculated bulk properties from the stream and uses them as the input bulk
properties for the new feed.
346
10 FCC Reactor
Tips:
l
To create a new virtual feed and assign it a default name as if it were an internal
stream, click Add.
To create a new virtual feed and initialize it with the data from the selected feed,
click Clone.
Even if the selected feed is a real stream, the clone/copy is flagged as a virtual feed.
10 FCC Reactor
Riser Bottom
Riser Midpoint
Riser1
Riser2
Riser1 Bottom
Riser1 Midpoint
Riser2 Bottom
Riser2 Midpoint
347
3. If you specify that the feed location should be Split, specify the fraction
of the feed to be injected at all possible locations.
4. If you wish, click Normalize to normalize the total composition to 1.
5. When you have finished specifying the feed location for this feed, perform one of the following tasks:
o
FCCReactor SectionTab
Specifying Feed Streams
Use the Feeds page on the Reactor Section tab of the FCC property view to
view and specify physical information about feeds.
The Feed Conditions group contains fields for each feed and recycled stream.
You can specify or view the following:
Field
Description
Volume flow
Mass flow
Temperature
Pressure
Location
The riser location(s) to which the feed is connected. The options available depend on the configuration of the FCC.
S Processed
Tip:To change the split of a feed, on the Feeds page, double-click the location column for
the feed in which you are interested. The Edit Splits dialog box appears, in which you can
change the split for the feed.
In the Feed Conditions group, for each feed, you can specify or view:
348
10 FCC Reactor
Volume flow
Mass flow
Temperature
Pressure
The Total Feed and Dispersion Steam group lets you specify details about
the feed and dispersion steam at each location. The number of columns varies
depending on the configuration of the FCC. The values of the following fields at
different riser locations are totaled in the Total column on the right.
l
For the Total Feed and Dispersion Steam group, at each feed location, you
can view:
Field
Description
Fresh Feed
Volume
Total Feed
Volume
The volume flow rate of the total feed (fresh feed + recycle) at this
location.
The mass flow rate of the total feed (fresh feed + recycle) at this location.
Or specify or view:
10 FCC Reactor
Field
Description
Steam Mass
The mass flow ratio of dispersion steam to the total feed at this
location.
Steam Temperature
Steam Pressure
349
Constant Ecat Metals. This option enables the calculation method that
keeps the Ecat metals data constant for both calibration and simulation
runs and calculates the bias of total feed metals.
Constant Feed Metals. This option enables the calculation method that
keeps the feed metals data constant for both calibration and simulation
runs.
o
In the calibration run, the Ecat metals are constant and the
biases of total feed metals are calculated. The biases of total
feed metals become part of the calibration factor set.
In the simulation run, the total feed metals biases are kept constant and the Ecat metal is calculated. You can overwrite the values of the feed metal biases.
The Feed Metals group displays the following variable information for each
feed stream:
Cell
Description
Vanadium
Nickel
Sodium
Iron
Copper
The Feed Metals Totals and Biases group contains the following objects:
Object
Description
Total column
Displays the metals weight (ppm) in the total feed for Vanadium,
Nickel, Sodium, Iron, and Copper.
Bias column
Displays the bias weight (ppm) in the total feed for Vanadium,
Nickel, Sodium, Iron, and Copper.
Restore Default
Biases button
Enables you to restore the default values (in other words, values in
the calibration set) in the Bias column.
Note:You can change the values in the Feed Metals Totals and Biases group only if you
selected the Constant Feed Metals radio button.
Tip:Click the Restore Default Biases button to restore the default values (values in the
selected calibration set) under the Bias column.
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10 FCC Reactor
The Equilibrium Catalyst group contains options that enable you to specify
the ppmwt for each of the ECAT metals, fresh make up rate, and MAT activity:
Field
Description
Vanadium
Nickel
Sodium
Iron
Copper
Description
Catalyst/Oil Ratio
If you specified two risers, you can specify or view this information for Riser1
and Riser2.
10 FCC Reactor
Field
Description
351
Field
Description
The Riser1-Riser 2
Bias
Temperature difference between Riser 1 and Riser 2 outlet temperatures (Riser 1 Riser 2).
Riser1 Catalyst/Oil
Ratio
Riser2 Catalyst/Oil
Ratio
In the Lift Gas Control group, you can specify or view the following information:
l
LiftGas Volume
LiftGas Mass
LiftGas Pressure
In the Reactor Stripping Zone group, you can specify or view the following
information:
Field
Description
Stripping steam mass flow rate per thousand of catalyst circulation rate.
352
10 FCC Reactor
The fields of the Regenerator group are described below. If you specified a
two-stage regenerator, you specify the following information for Stage 1 and
Stage 2.
Field
Description
Cyclone Temperature
EnrichO2 Pressure
EnrichO2 pressure.
Enrich O2 Temperature
Enrich O2 temperature.
Catalyst Inventory
Flue QuenchWaterRate
Flue Quench WaterTemp
Flue Quench Water Pressure
The Ambient Air Conditions group contains three fields, which are described
below.
10 FCC Reactor
Field
Description
Temperature
Pressure
Relative Humidity
353
If you specified a two-stage Regenerator for the FCC, the Stage 1 Conditions
group appears. This group contains two tables, which are described below.
Description
Apparent
Bias
CRC
Row
Description
Apparent
Bias
The apparent dense bed temperature and CRC are primarily used in the calibration. They are treated as part of the measurements for the first stage regenerator. The bias is the difference between the apparent and the calculated
values (Apparent Calculated). It is the indication of the quality of the data. If
the quality of the data is good, the apparent value should be close to the calculated one.
354
Cell
Description
Reactor Pressure
Regenerator Pressure
Regenerator - Reactor
Pressure Difference
The pressure difference between the top of the regenerator and the reactor.
The pressure difference between the bottom of the regenerator and the bottom of the riser.
10 FCC Reactor
If the FCC has one riser and a two-stage regenerator, the Pressure Control
group contains five fields, which are described below.
Cell
Description
Reactor Pressure
If the FCC has two risers, the Pressure Control group contains five fields,
which are described in the following table:
Cell
Description
Reactor Pressure
Regenerator Pressure
The pressure difference between the top of the regenerator and the reactor.
The pressure difference between the bottom of the regenerator and the bottom of Riser 1.
The pressure difference between the bottom of the regenerator and the bottom of Riser 2.
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355
From the Initialization drop-down list, specify how the Hessian is initialized.
Option
Description
Normal
(Default)
Hessian initialized with identity matrix. This setting balances efficiency and robustness. It is well suited for general purpose optimization problems. Typical applications
are offline optimization and online problems that start
very far from a solution.
Aggressive
Scaled
Advanced
Hessian initialized with 2nd order information. Recommended for problems with many Degrees of Freedom at
solution and/or quadratic objective function. Ideal for
data reconciliation problems, both online and offline.
356
From the Initialization drop-down list, specify how the Hessian is initialized.
10 FCC Reactor
Description
Normal
(Default)
Exact
A well-known exact penalty line search. It is too conservative for most practical problems.
Residual
A proprietary line search designed to initially favor the convergence of residuals over the objective function improvement.
Square
From the Step Control drop-down list, specify how large the
steps will be.
Option
Description
Normal
(Default)
Aggressive
Conservative
10. In the Failure Recovery Action group, you can specify which action
the solver should take in the event of failure:
o
Do nothing
10 FCC Reactor
357
To clear the messages in the Simulation Engine Message and Script Commands
field, click Clear Message.
358
10 FCC Reactor
In the Advanced Tuning Parameters section, you can set the following:
Parameter
Type
Coke Distribution
Fraction Concarbon to
coke
Non-vaporized feed to
coke
Mass ratio of
H2 to metals
coke
Gasoline Overcracking
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359
Parameter
Type
Pre-exponential
factor for
Gasoline
Cracking
Natural log of the pre-exponential factor for first order reaction rate for
naphtha cracking to gas lump.
Ea/R for
Gasoline
Cracking
Catalyst
stripper term
Riser/rxtr
term on
regen bed
side
Heat released by adsorption and desorption of kinetic coke on the catalyst in regenerator dense bed.
Catalyst
stripper term
on regen bed
side
Regen dilute
phase term
Catalyst split factor around reactor dilute phase. Fraction of total cat circ
that bypasses reactor dilute phase directly to the stripper.
360
enter
Natural log of the pre-exponential factor for the first order cracking of
light paraffin (L-P) to light gases (C-lump).
10 FCC Reactor
Parameter
Type
Distillate
naphthenic
cracking to C
lump
Natural log of the pre-exponential factor for the first order cracking of
light naphthenic (L-N) to light gases (C-lump).
Natural log of the pre-exponential factor for the first order cracking of
light aromatic sidechains (L-As) to light gases (C-lump).
Natural log of the pre-exponential factor for the first order cracking of
light paraffin (L-P) to gasoline (G-lump).
Distillate
naphthenic
cracking to G
lump
Natural log of the pre-exponential factor for the first order cracking of
light naphthenic (L-N) to gasoline (G-lump).
Natural log of the pre-exponential factor for the first order cracking of
light aromatic sidechains (L-As) to gasoline (G-lump).
Natural log of the pre-exponential factor for the first order cracking of
light aromatic cores (L-As) to gasoline (G-lump).
Natural log of the bias between the cracking of resid to Light (430-650)
and Heavy (650-950) components. A value of zero means that a resid
cracks 50/50 to light and heavy. A value of .693 (ln 2) would mean that
resid cracks twice as fast to light compared to heavy.
10 FCC Reactor
Methane
from feed
light paraffin
Methane
from feed
light naphthenics
Methane
from feed
light aromatic sidechains
361
Parameter
Type
Methane
from feed
heavy paraffin
Methane
from feed
heavy naphthenics
Methane
from feed
heavy aromatic sidechains
Methane
from feed
resid paraffin
Methane
from feed
resid naphthenics
Methane
from feed
resid aromatic sidechains
Ethane from
Parameter that changes the response of ethane generated from light
feed light par- paraffin cracking.
affin
Ethane from
feed light
naphthenics
Ethane from
Parameter that changes the response of ethane generated light arofeed light aro- matic sidechain cracking.
matic sidechains
362
Ethane from
feed heavy
paraffin
Ethane from
feed heavy
naphthenics
10 FCC Reactor
10 FCC Reactor
Parameter
Type
Ethane from
feed heavy
aromatic
sidechains
Ethane from
feed resid
paraffin
Ethane from
feed resid
naphthenics
Ethane from
feed resid
aromatic
sidechains
Ethylene
from feed
light paraffin
Ethylene
from feed
light naphthenics
Ethylene
from feed
light aromatic sidechains
Parameter that changes the response of ethylene generated light aromatic sidechain cracking.
Ethylene
from feed
light 1-ring
aromatic
cores
Ethylene
from feed
light 2-ring
aromatic
cores
Ethylene
from feed
heavy paraffin
363
364
Parameter
Type
Ethylene
from feed
heavy naphthenics
Ethylene
from feed
heavy aromatic sidechains
Ethylene
from feed
heavy 1-ring
aromatic
cores
Ethylene
from feed
heavy 2-ring
aromatic
cores
Ethylene
from feed
heavy 3-ring
aromatic
cores
Ethylene
from feed
resid paraffin
Ethylene
from feed
resid naphthenics
Ethylene
from feed
resid aromatic sidechains
Ethylene
from feed
resid 1-ring
aromatic
cores
10 FCC Reactor
Parameter
Type
Ethylene
from feed
resid 2-ring
aromatic
cores
Ethylene
from feed
resid 3-ring
aromatic
cores
ThermalCracking
10 FCC Reactor
Entry zone
cracking
activity
Entry zone
EA over RT
(1000F)
Post riser
cracking
activity
Post riser EA
over RT
(1000F)
Activation energy of the thermal cracking reaction at the post riser section.
Light Gas
Delumping
to Hydrogen
Light Gas
Delumping
to Ethane
Light Gas
Delumping
to Ethylene
Light Gas
Delumping
to Propane
Light Gas
Delumping
to Propylene
Light Gas
Delumping
to i-Butane
365
Parameter
Type
Light Gas
Delumping
to n-Butane
Light Gas
Delumping
to Butylenes
CRC Response
CRC
Response
Intercept
CRC
Response
Slope
MAT Tuning
Global Catalyst Deactivation Factor
Catalyst
Activity vs.
Cracking
Factor
Catalyst
Activity vs.
Coking
Factor
In the Property Correlation Multipliers group, from the Property dropdown list, select a property and then specify the correlation multipliers for the
property.
You can set property correlation multipliers for the following properties that
have more than just the Overall factor. The properties and their correlation
multiplier fields are described below.
Sulfur
366
Field
Description
10 FCC Reactor
LCO - Conversion
Bottoms - Conversion
Gravity
10 FCC Reactor
Field
Description
367
Field
Description
LCO UOPK
LCO - Conversion
Bottoms UOPK
Bottoms - Conversion
Olefins
368
Field
Description
LCO UOPK
LCO - Conversion
10 FCC Reactor
Field
Description
Bottoms UOPK
Bottoms - Conversion
Naphthenics
10 FCC Reactor
Field
Description
LCO UOPK
LCO - Conversion
369
Field
Description
Bottoms UOPK
Bottoms - Conversion
Aromatics
370
Field
Description
LCO UOPK
LCO - Conversion
10 FCC Reactor
Field
Description
Bottoms UOPK
Bottoms - Conversion
Cloud Point
Field
Description
RON
Field
Description
MON
10 FCC Reactor
Field
Description
371
Field
Description
EO Variables
This grid lists all of the variables and their attributes. It may be used to change
the attributes of a variable. Whenever an attribute is changed, its background
color becomes yellow.
You can sort the variable list by any attribute in ascending and descending
order.
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If any variable attributes have been changed, their Modified entry becomes
checked. To sort by Modified, double-click the Modified column header.
Fractionator Tab
Specifying Zones Pressures
Use the Zone Pressures page of the Fractionator tab of the FCC property
view to specify the top pressure values for the Fractionator zones.
You can specify the top zone pressure for the fractionator cuts you specified on
the first page of the Configuration Wizard except:
l
Light ends
372
10 FCC Reactor
Specification options
This data is used for simulation runs. A simulation run is a simple what-if
study. It shows which changes to dependent variables result from a specified
set of independent variables.
To access the Specs page:
1. Select the Reactor Section tab | Specs page for the FCCReactor.
The Specs page appears. On the Specs page, you can set one of two
Spec Options:
o
10 FCC Reactor
Molar
Mass
Liquid Volume
373
Notes:
l
The Actual Residue stream flow rate. The Actual Residue stream flow
rate is based on the TBP cut point or the Feed fraction values specified by
you.
The Minimum and Actual flow rate values are used to indicate how successfully the
column will converge in Stage-by-stage solver modes.
o
If the Minimum flow rate is more than the Actual flow rate, the column
will not converge.
If the Minimum flow rate is equal or less than the Actual flow rate, the
column will converge.
Conditions
Properties
Composition
374
10 FCC Reactor
Page
Description
Feed Blend
Product
Yields
Displays the standard cut yields, and fractionated cut yields if a fractionator is included, from the simulation.
Product Properties
Riser/Reactor
Regenerator
Fractionator
Heat Balance
Advanced
10 FCC Reactor
375
Blend Properties
Bulk properties
API Gravity
Ca Meas
Viscosity CSt@210F
Lab
Viscosity, SUS@210F
Lab
Viscosity CSt@210F
Est.
Sulfur Content
Fraction of
Feed S Processed
D1160 VABP
K Factor based on
D1160 VAPB
K Factor based on
D2887 50% point
Hydrogen content
Molecular weight
Conradson
carbon
residue
l
376
Ramsbottom
carbon
residue
RI @Specified
T Meas
RI Meas. Temperature
RI @ 20C
Calc. from
Lab Data
RI @20C est.
from Bulk.
Prop
10 FCC Reactor
Blend Properties
Distribution data
D2887 Initial
point
D2887 5%
point
D2887 30%
point
D2887 50%
point
D2887 70%
point
10 FCC Reactor
D2887 10%
point
D2887 90%
point
D2887 95%
point
D2887 Endpoint
D1160 Initial
point
D1160 5%
point
D1160 10%
point
D1160 30%
point
D1160 50%
point
D1160 70%
point
D1160 90%
point
D1160 95%
point
D1160 Endpoint
TBP 5% point
TBP Endpoint
D86 5% point
D86 Endpoint
377
Blend Properties
Base Kinetic Lump composition
C1-C4 lump
C5-430 lump
950+ Paraffins
950+ Naphthenes
Totals
430-650
Paraffins
l
430-650
Naphthenes
378
430-650
One-ring aromatics
430-650
Two-ring aromatics
650-950
Paraffins
650-950
Naphthenes
10 FCC Reactor
Blend Properties
Adjusted Kinetic Lump Composition Detail
C1-C4 lump
C5-430 lump
950+ Paraffins
950+ Naphthenes
Totals
430-650
Paraffins
l
430-650
Naphthenes
430-650
Two-ring aromatics
650-950
Paraffins
650-950
Naphthenes
C1-C4 lump
650-950 lump
C5-430 lump
950+ lump
430-650
lump
Totals
C1-C4 lump
One-ring aromatics
C5-430 lump
Two-ring aromatics
Paraffins
Naphthenes
Aromatic sidechains
Aromatic sidechains
Totals
10 FCC Reactor
430-650
One-ring aromatics
379
Blend Properties
Composition For Flash Calculations
Pseudo250
Pseudo280
Pseudo610
Pseudo640
Pseudo670
Pseudo310
Pseudo700
Pseudo340
Pseudo750
Pseudo370
Pseudo800
Pseudo400
Pseudo850
Pseudo900
Pseudo950
Pseudo1050
Pseudo1150
Pseudo1250
Pseudo2000
Pseudo430
Pseudo460
Pseudo490
Pseudo520
Pseudo550
Pseudo580
Note: For the fractionated yields, the liquid product cuts correspond to those specified on
the Configuration Wizard.
380
10 FCC Reactor
Volume Flow
H2S
Butenes
Mass Flow
Fuel Gas
Volume %
Propane
C5+ Naphtha
l
l
Weight %
Propylene
LCO
Bottoms
Coke
Total Conversion
n-Butane
i-Butane
Volume Flow
H2S
Cyclopentane
Mass Flow
Hydrogen
3m1-Butene
Volume %
Methane
1-Pentene
Weight %
Ethane
2m1-Butene
Ethylene
c2-Pentene
Propane
t2-Pentene
Propylene
2m2-Butene
n-Butane
Cyclopentene
i-Butane
Isoprene
1-Butene
Benzene
c2-Butene
C5+ Naphtha
t2-Butene
LCO
Butadene
Bottoms
n-Pentane
Coke
i-Pentane
Total Conversion
10 FCC Reactor
381
Volume Flow
H2S
Mass Flow
Fuel Gas
Volume %
C3 in
LPG
Weight %
l
C4 in
LPG
C5+ in
LPG
Light
Naphtha
Medium
Naphtha
Heavy
Naphtha
Light LCO
Heavy LCO
HCO
Bottoms
Coke
Total Conversion
382
Volume Flow
H2S
1-Pentene
Mass Flow
Hydrogen
2m1-Butene
Volume %
Methane
c2-Pentene
Weight %
Ethane
t2-Pentene
Ethylene
2m2-Butene
Propane
Cyclopentene
Propylene
Isoprene
n-Butane
C6+ in LPG
i-Butane
1-Butene
Light Naphtha
l
l
c2-Butene
Medium Naphtha
t2-Butene
Heavy Naphtha
Butadene
n-Pentane
Light LCO
i-Pentane
Heavy LCO
Cyclopentane
HCO
3m1-Butene
Bottoms
Coke
Total Conversion
10 FCC Reactor
Fractionated products.
Note: For Fractionated products, the product cuts are those you specified on the Configuration Wizard.
API Gravity
l
Specific Gravity
Sulfur %
Concarbon %
Fractionated Products
The Product Properties group displays the following values for each of
streams listed:
10 FCC Reactor
383
API
Gravity
l
Specific
Gravity
Sulfur
%
Olefins %
l
Naphthenes %
Aromatics %
Concarbon %
Basic Nitrogen
(ppmwt)
RON
l
MON
(R+M)
/2
RVP
C4 Content
Paraffins %
Dewpoint temperature
Mix temperature
Mix pressure
Total
Riser
Riser
384
10 FCC Reactor
l
l
Riser (kg)
Reactor dilute phase (kg)
Note: For dual riser configuration, there will be one column for each riser. In addition,
there is a field displaying the Total Catalyst Inventory.
Cyclone Temperature
Flue Gas O2
Flue Gas CO
O2 Injection Temperature
Catalyst Inventory
In the Regenerator Air Supply Summary group, the Regenerator page displays:
Argument
Mole Flows
10 FCC Reactor
Description
l
385
Argument
Mass Flows
Volume Flows
Temperatures
Pressures
386
Description
l
Enrich O2 temperature
Enrich O2 pressure
Wet Air N2
Wet Air O2
Enriched Air N2
Enriched Air O2
Enriched Air CO
10 FCC Reactor
Coke Yield
For the riser (or Riser 1 and Riser 2 if the FCC has two
risers)
l
l
CRC %
10 FCC Reactor
387
FCC Environment
The environment design concept is one of the cornerstones on which HYSYS is
built. These environments let you access and input information in a certain area
(environment) of the simulation, while other areas of the simulation are put on
hold. The other areas will not proceed with steady state calculations until you
are finished working in the active area. Since the HYSYS integrator is time-step
based, the environments have no impact on dynamic calculations.
Separate Desktops are available within each environment. These Desktops
include an appropriate menu bar, tool bar, and Home View(s) specifically
designed for interaction with that particular environment. The Desktops also
remember the property views that are open, even when their associated environment is not currently active.
When moving from one environment to another, Desktops provide a mechanism for quickly and automatically putting away any property views that are
open in one environment, and bringing up the property views that were open
in the other environment. This feature is useful when working with large flowsheets.
When beginning a HYSYS simulation, you automatically start in the Simulation
Properties environment. Here you create, define, and modify fluid packages to
be used by the simulations flowsheets. In general, a fluid package containsat
minimuma property package and library and/ or hypothetical components.
Fluid packages can also contain information such as reactions and interaction
parameters.
388
10 FCC Reactor
This flowsheet serves as the base level or Main flowsheet for the whole simulation case. Any number of subflowsheets can be generated in this main flowsheet. While there is only one main flowsheet environment, each individual
subflowsheet that is installed can have its own corresponding subflowsheet
environment.
The FCC Environment is a subflowsheet to the Main flowsheet for the whole simulation case.
The following diagram shows the relationship of the FCC Environment to the
HYSYS hierarchy.
Configure FCCs
Calibrate FCCs
10 FCC Reactor
389
Configuration
Geometry
Heat Loss
Notes
Tip:To change any of the specifications on this page, click Configuration Wizard to
launch the Configuration Wizard.
390
Risers
Strippers
Regenerators
10 FCC Reactor
Tip:To change any of the specifications on this page, click Configuration Wizard to
launch the Configuration Wizard.
If the FCC has a single-stage regenerator, the Regenerator group displays the
following information:
l
Interface Diameter
If the FCC has a two-stage regenerator, the Regenerator section displays the
following information for Stage 1 and Stage 2 of the Regenerator:
l
Interface Diameter
10 FCC Reactor
391
Tip:To change any of the specifications on this page, click Configuration Wizard to
launch the Configuration Wizard.
392
10 FCC Reactor
The following table lists and describes the objects on the Library page:
Object
Description
Available
Feed
Types list
Edit button
Enables you to edit the selected feed type in the Available Feed Types
list.
Add button
Enables you to add a feed type to the FCC. The FCCFeed Type Property
view appears.
Delete
button
Enables you to remove the selected feed type (in the Available Feed
Types list) from the FCC.
Clone button
Enables you to clone the selected feed type in the Available Feed Types
list.
Import
button
Enables you to import a feed type (from a file) into the FCC.
Export
button
Enables you to export the selected feed type (in the Available Feed
Types list) to a file. The exported feed type can be imported into a different
FCC operation.
Note: By default, data for a VGO feed is filled in when you click Add a Feed Type. A library of Feed Types containing multiple Feed Types is provided in the FCC/FeedLibrary
subfolder of your installation folder. You can import one or more of them to your simulation.
10 FCC Reactor
393
394
10 FCC Reactor
Enter data on this page for use in a simulation run. A simulation run is a
simple what-if study. It shows which changes to dependent variables result
from a specified set of independent variables.
To specify feed properties:
1. From the Feeds list, select from the available feeds.
2. You can select one of three Feed Properties methods.
o
Assay
Bulk Properties
Kinetic Lumps
The FCC model uses these feed properties and the specified Feed Type
to generate kinetic lumps of the feed for the simulation.
When you select a feed in the list box, the rest of the form is filled out
with the data for the selected feed. If the feed is a real stream, then you
cannot choose a property method. You can change only the feed name
and the feed type.
If you clone a riser feed which is mapped to an external stream, HYSYS
copies the calculated bulk properties from the stream and uses them as
the input bulk properties for the new feed.
o
Tips:
o
To create a new virtual feed and initialize it with the data from the selected feed, click Clone.
Even if the selected feed is a real stream, the clone/copy is flagged as a
virtual feed.
3. In the Properties of Selected Feed table, you can view and edit properties. The type of stream properties available for modification depends
on the method you select in the Feed Properties group. If you select the:
Assay Property method
10 FCC Reactor
Field
Description
Name
Feed
Type
The feed type. Select the feed type from the drop-down list. The feed
types available are those in the Available Feed Types list on the
Library Page of the Feed Data tab.
Assay
Name
395
Field
Description
Top
Cut
Point
Bottom
Cut
Point
The bulk properties calculated from the assay and the cut points appear.
Bulk properties property method
Field
Description
Name
Feed Type
The feed type. Select the feed type from the drop-down list. The
feed types available are those in the Available Feed Types list
on the Library page of the Feed Data tab.
API Gravity
Specific Gravity
Distillation
type
396
TBP
D86
D1160
D2887
Initial Point
5% Point
10% Point
30% Point
50% Point
70% Point
90% Point
95% Point
Endpoint
Basic Nitrogen
Total Nitrogen
10 FCC Reactor
10 FCC Reactor
Field
Description
Total/Basic
Nitrogen
Ratio
Sulfur Content
Fraction of
Feed S Processed
Conradson
Carbon
Residue
Ramsbottom
Carbon
Residue
RI @Specified T Meas.
(Optional)
RI Meas.
Temperature
(Optional)
RI @20C
Calc. from
Lab Data
RI @20C
Est. from
Bulk Prop.
Ca Meas.
(Optional)
Ca Est. from
Total Method
Viscosity,
cSt@210F
Lab.
(Optional)
Viscosity,
SUS@210F
Lab.
(Optional)
397
Field
Description
Viscosity,
cSt@210F
Est.
Vanadium
Nickel
Sodium
Iron
Copper
Description
Name
Feed Type
The feed type. Select the feed type from the drop-down list. The
feed types available are those in the Available Feed Types list
on the Library page of the Feed Data tab.
C1-C4 Lump
C5-430
Lump
430-650
Paraffins
430-650
Naphthenes
398
430-650
One ring Aromatics
430-650
Two ring Aromatics
650-950
Paraffins
650-950
Naphthenes
10 FCC Reactor
Field
Description
650-950
Two ring Aromatics
650-950
Three+ ring
Aromatics
950+
Paraffins
950+ Naphthenes
950+ One
ring Aromatics
950+ Two
ring Aromatics
950+
Three+ ring
Aromatics
API Gravity
Distillation
type
10 FCC Reactor
TBP
D86
D1160
D2887
Initial Point
5% Point
10% Point
30% Point
50% Point
399
Field
Description
70% Point
90% Point
95% Point
Endpoint
Basic Nitrogen
Total Nitrogen
Total/Basic
Nitrogen
Ratio
Sulfur Content
Fraction of
Feed S Processed
Conradson
Carbon
Residue
Ramsbottom
Carbon
Residue
Vanadium
Nickel
Sodium
Iron
Copper
Note: If the feed is connected to external stream, then you cannot choose a Property Method. You can only change the feed name and the feed type.
400
10 FCC Reactor
Note: By default, HYSYSestimates the refractive index from other bulk properties to
ensure high quality results. We recommend that you only select this check box if you are
confident that the refractive index data from the stream is accurate.
Catalyst Tab
Selecting Catalysts for the FCC Reactor
Use the Library page of the Catalyst tab of the FCC Reactor Section property
view to manage the library of catalysts for a simulation run. A simulation run
is a simple what-if study. It shows which changes to dependent variables result from a specified set of independent variables.
The Available Catalysts field shows the list of catalysts available.
A Catalyst library containing multiple catalysts is provided in the
FCC/CatLibrary subfolder of your installation folder. You can import one or
more of them to your simulation.
The following table lists and describes the objects on the Library page:
Object
Description
Available
Catalyst
list
Edit button
Enables you to edit the selected catalyst in the Available Feed Types list.
Add button
Delete
button
Enables you to remove the selected catalyst (in the Available Feed Types
list) from the FCC reactor.
Clone
button
Enables you to clone the selected catalyst in the Available Feed Types list.
Import
button
Enables you to import a catalyst (from a file) into the FCC reactor.
Export
button
Enables you to export the selected catalyst (in the Available Feed Types list)
to a file. The exported catalyst can be imported into a different FCC operation.
10 FCC Reactor
401
Section icon
2. On the FCC Reactor Section property view, select the Catalyst tab |
Blend page.
On the Blend page, you can:
l
Specify the weight fraction of each catalyst in the blend when you have
multiple catalysts.
Note: To view and edit the details of the blend, and to delete blends, click Blend
Details.
l
l
The Base Catalyst Blend and Composition group contains the following
options:
402
Object
Description
Zeolite row
The calculated amount of Zeolite in the catalyst. You can override the
amount of Zeolite in the catalyst.
Alumina
row
The calculated amount of Alumina in the catalyst. You can override the
amount of Alumina in the catalyst.
Rare Earth
row
The calculated amount of Rare Earth in the catalyst. You can override
the amount of Rare Earth in the catalyst.
Normalize
button
Blend
Details button
10 FCC Reactor
Object
Description
Export
Blend button
If you have more than one catalyst in the base catalyst blend, you must
specify the weight fraction of each catalyst in the blend.
The default values of Zeolite, Alumina, and Rare Earth are displayed in
red when you add the catalyst to the blend. You can overwrite these values. The Base Catalyst Blend is always calculated using the normalized
weight fraction of the catalysts.
The Total column displays the blended values for Zeolite, Alumina, and
Rare Earth.
You can specify details about the ZSM-5 Additive. The ZSM-5 Additive group
contains the following two fields:
Field
Description
Selectivity
ZSM-5 Per
Unit Mass of
Base Blend
Standard (default)
High
The amount of ZSM-5 Additive per Unit Mass of the Base Blend.
Note: The ZSM-5 per Unit Mass of Base Blend is the fraction of ZSM-5
zeolite crystal in the total blend (and not the fraction of total additive
in the total blend).
Description
10 FCC Reactor
403
Section icon
2. On the FCC Reactor Section property view, select the Catalyst tab |
Activity page.
The Option for Specifying Metals Balance group enables you to select the
following options:
l
Constant Ecat Metals. This option enables the calculation method that
keeps the Ecat metals data constant for both calibration and simulation
runs, and calculates the bias of total feed metals.
Constant Feed Metals. This option enables the calculation method that
keeps the feed metals data constant for both calibration and simulation
runs.
o
In the calibration run, the Ecat metals are constant and the
biases of total feed metals are calculated. The biases of total
feed metals become part of the calibration factor set.
In the simulation run, the total feed metals biases are kept constant and the Ecat metal is calculated. You can overwrite the values of the feed metal biases.
The Feed Metals group displays the following variable information for each
feed stream:
404
10 FCC Reactor
Cell
Description
Vanadium
Nickel
Sodium
Iron
Copper
The Feed Metals Totals and Biases group contains the following objects:
Object
Description
Total column
Displays the total weight (ppm) of the following catalyst: Vanadium, Nickel, Sodium, Iron, and Copper.
Bias column
Displays the bias weight (ppm) of the following catalyst: Vanadium, Nickel, Sodium, Iron, and Copper.
Restore Default
Biases button
Enables you to restore the default values (in other words, values in
the calibration set) in the Bias column.
Note: You can change the values in the Feed Metals Totals and Biases group only if
you selected the Constant Feed Metals radio button.
Tip:Click the Restore Default Biases button to restore the default values (values in the
selected calibration set) under the Bias column.
The Equilibrium Catalyst group contains options that enable you to specify
the ppmwt for each of the ECAT metals, fresh make up rate, and MAT activity:
Field
Description
Vanadium
Nickel
Sodium
Iron
Copper
Catalyst Inventory
Fresh Make Up Rate(kg/h)
Note: The metals in equilibrium catalyst include the amounts from both the feed and the
base catalyst.
10 FCC Reactor
405
Operation Tab
Specifying Feed Data
Use the Feeds page on the Operation tab of the FCC Reactor Section property
view to view and specific physical information about feeds.
This data is used for simulation runs. A simulation run is a simple what-if
study. It shows which changes to dependent variables result from a specified
set of independent variables.
1. In the Feed Conditions group, specify or view the following information for each feed stream in the FCC reactor.
Field
Description
Volume Flow
Mass Flow
Temperature
Pressure
Location
Note: If there is more than one riser location, you can double-click the name of
the feed to open the dialog box that allows you to split the feed to different locations.
2. In the Total Feed and Dispersion Steam group, specify the following
parameters for each appropriate point:
406
Field
Description
Steam Volume
Steam Mass
Steam Pressure
Steam Temperature
10 FCC Reactor
Configuring FCCRisers/Reactors
Use the Riser/Reactor page on the Operation tab of the FCC Reactor Section
property view to specify details about riser and reactor operating conditions.
Note:This data is used for simulation runs. A simulation run is a simple what-if study.
It shows which changes to dependent variables result from a specified set of independent
variables.
1. In the Riser Temperature Control group, you can specify the following information that controls the temperature of the riser(s).
If the FCC has one riser, the Riser Temperature Control group contains four fields:
Field
Description
Catalyst/Oil Ratio
If the FCC has two risers, the Riser Temperature Control group contains eight fields:
Field
Description
The Riser1-Riser 2
Bias
Temperature difference between Riser 1 and Riser 2 outlet temperatures (Riser 1 Riser 2).
Reactor Plenum
Temperature
Riser1 Catalyst/Oil
Ratio
Riser2 Catalyst/Oil
Ratio
2. In the Lift Gas ControlGroup section, you can specify the following
information:
10 FCC Reactor
407
LiftGas Pressure
Description
408
Field
Description
Cyclone Temperature
10 FCC Reactor
Field
Description
Enrich O2 Temperature
Enrich O2 temperature.
Catalyst Inventory
Description
Temperature
Pressure
Relative Humidity
Description
Apparent
Bias
CRC table
10 FCC Reactor
Row
Description
Apparent
Bias
409
Reactor Pressure
Regenerator Pressure
The options available for input depend on the specifications you made on the
Design page.
Note:This data is used for simulation runs. A simulation run is a simple what-if study.
It shows which changes to dependent variables result from a specified set of independent
variables.
If the FCC has one riser and a single-stage regenerator, the Pressure Control
group contains four fields:
Field
Description
Reactor Pressure
Regenerator Pressure
The pressure difference between the top of the regenerator and the reactor.
The pressure difference between the bottom of the regenerator and the bottom of the riser.
If the FCC has one riser and a two-stage regenerator, the Pressure Control
group contains five fields:
Field
Description
Reactor Pressure
If the FCC has two risers, the Pressure Control group contains five fields:
410
10 FCC Reactor
Field
Description
Reactor Pressure
Regenerator Pressure
The pressure difference between the top of the regenerator and the reactor.
The pressure difference between the bottom of the regenerator and the bottom of Riser 1.
The pressure difference between the bottom of the regenerator and the bottom of Riser 2.
tion icon
Section icon
2. On the FCC Reactor Section property view, select the Operation tab |
Solver Options page.
3. In the Convergence Tolerance group, in the Residual field, specify
the largest residual allowed for convergence.
4. In the IterationLimits section, specify the following fields.
10 FCC Reactor
Field
Description
Maximum Iterations
411
Field
Description
Minimum Iterations
5. In the Creep Step Parameters group, specify the following fields. Use
this group to specify details about how the creep function of the DMO
Solver should perform.
Field
Description
On / Off
Switch
Iterations
Step Size
Description
Normal
(Default)
Hessian initialized with identity matrix. This setting balances efficiency and robustness. It is well suited for general purpose optimization problems. Typical applications are offline optimization and
online problems that start very far from a solution.
Aggressive
Hessian initialized with small values. This setting moves the problem to bounds faster than the Normal mode. This setting is preferred for highly constrained optimization problems with few
Degrees of Freedom at solution. Ideal applications are well-posed
online real-time optimization problems.
Scaled
A combination of the Aggressive and Advanced modes. Recommended for highly constrained optimization problems with few
Degrees of Freedom at solution and a nonlinear objective function.
Advanced
nd
8. In the Scaling factor field, specify the scaling factor to apply to the Hessian.
9. In the Updates stored field, specify the number of updates stored. The
default is 10.
412
10 FCC Reactor
Description
Normal
(Default)
Exact
A well-known exact penalty line search. It is too conservative for most practical problems.
Residual
A proprietary line search designed to initially favor the convergence of residuals over the objective function improvement.
Square
Description
Normal
(Default)
Aggressive
Conservative
11. In the Variable Scaling Parameter group, from the On/Off Switch
drop-down list:
o
12. The Failure Recovery Action group contains a drop-down list that
enables you to select what the DMO Solver should do in the case of failure. The choices are:
o
Do nothing
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
10 FCC Reactor
413
Description
Enables you to enter the text code for a command for the
solver.
Enables you to retrieve a previous command from the command history and place the text code in the Enter Script
Command field.
Enables you to retrieve the next command from the command history and place the text code in the Enter Script
Command field.
414
10 FCC Reactor
enter
Performance slope
enter
enter
10 FCC Reactor
enter
415
enter
Pre-exponential factor
for Gasoline Cracking
Natural log of the pre-exponential factor for first order reaction rate for naphtha cracking to gas lump.
enter
Regenerator dilute
phase flux parameter
enter
Riser/reactor term
Heat released by adsorption and desorption of coke on the catalyst in riser reactor section.
Heat released by adsorption and desorption of coke on the catalyst in catalyst stripper.
Riser/rxtr term on
regen bed side
Heat released by adsorption and desorption of coke on the catalyst in regenerator dilute phase.
416
enter
10 FCC Reactor
10 FCC Reactor
For this
parameter
enter
Distillate
paraffin
cracking to
C lump
Natural log of the pre-exponential factor for the first order cracking of
light paraffin (L-P) to light gases (C-lump).
Distillate
naphthenic
cracking to
C lump
Natural log of the pre-exponential factor for the first order cracking of
light naphthenic (L-N) to light gases (C-lump).
Distillate
aromatic
sidechain
cracking to
C lump
Natural log of the pre-exponential factor for the first order cracking of
light aromatic sidechains (L-As) to light gases (C-lump).
Distillate
paraffin
cracking to
G lump
Natural log of the pre-exponential factor for the first order cracking of
light paraffin (L-P) to gasoline (G-lump).
Distillate
naphthenic
cracking to
G lump
Natural log of the pre-exponential factor for the first order cracking of
light naphthenic (L-N) to gasoline (G-lump).
Distillate
aromatic
sidechain
cracking to
G lump
Natural log of the pre-exponential factor for the first order cracking of
light aromatic sidechains (L-As) to gasoline (G-lump).
Distillate
aromatic
ring cracking to G
lump
Natural log of the pre-exponential factor for the first order cracking of
light aromatic cores (L-As) to gasoline (G-lump).
Natural log of the bias between the cracking of resid to Light (430-650)
and Heavy (650-950) components. A value of zero means that a resid
cracks 50/50 to light and heavy. A value of .693 (ln 2) would mean that
resid cracks twice as fast to light compared to heavy.
417
enter
Parameter that changes the response of methane generated from light paraffin cracking.
Parameter that changes the response of methane generated from light naphthenic cracking.
Parameter that changes the response of methane generated from light aromatic sidechain cracking.
Parameter that changes the response of methane generated from heavy paraffin cracking.
Parameter that changes the response of methane generated from heavy naphthenic cracking.
Parameter that changes the response of methane generated from heavy aromatic sidechain cracking.
Parameter that changes the response of methane generated from resid paraffin cracking.
Parameter that changes the response of methane generated from resid naphthenic cracking.
Parameter that changes the response of methane generated from resid aromatic sidechain cracking.
Parameter that changes the response of ethane generated from light paraffin cracking.
Parameter that changes the response of ethane generated from light naphthenic cracking.
Parameter that changes the response of ethane generated light aromatic sidechain cracking.
Parameter that changes the response of ethane generated from heavy paraffin cracking.
Parameter that changes the response of ethane generated from heavy naphthenic cracking.
Parameter that changes the response of ethane generated from heavy aromatic sidechain cracking.
Ethane from feed resid par- Parameter that changes the response of ethane genaffin
erated from resid paraffin cracking.
Ethane from feed resid
naphthenics
418
Parameter that changes the response of ethane generated from resid naphthenic cracking.
10 FCC Reactor
enter
Ethane from feed resid aro- Parameter that changes the response of ethane genmatic sidechains
erated from resid aromatic sidechain cracking.
10 FCC Reactor
Parameter that changes the response of ethylene generated from light paraffin cracking.
Parameter that changes the response of ethylene generated from light naphthenic cracking.
Parameter that changes the response of ethylene generated light aromatic sidechain cracking.
Parameter that changes the response of ethylene generated from light 1-ring aromatic cores.
Parameter that changes the response of ethylene generated from light 2-ring aromatic cores.
Parameter that changes the response of ethylene generated from heavy paraffin cracking.
Parameter that changes the response of ethylene generated from heavy naphthenic cracking.
Parameter that changes the response of ethylene generated from heavy aromatic sidechain cracking.
Parameter that changes the response of ethylene generated from heavy 1-ring aromatic cores.
Parameter that changes the response of ethylene generated from heavy 2-ring aromatic cores.
Parameter that changes the response of ethylene generated from heavy 3-ring aromatic cores.
Parameter that changes the response of ethylene generated from resid paraffin cracking.
Parameter that changes the response of ethylene generated from resid naphthenic cracking.
Parameter that changes the response of ethylene generated from resid aromatic sidechain cracking.
Parameter that changes the response of ethylene generated from resid 1-ring aromatic cores.
Parameter that changes the response of ethylene generated from resid 2-ring aromatic cores.
Parameter that changes the response of ethylene generated from resid 3-ring aromatic cores.
419
enter
420
10 FCC Reactor
Sulfur
10 FCC Reactor
Field
Description
LCO - Conversion
Bottoms - Conversion
421
Gravity
Field
Description
LCO UOPK
LCO - Conversion
Bottoms UOPK
Bottoms - Conversion
Olefins
422
Field
Description
10 FCC Reactor
LCO UOPK
LCO - Conversion
Bottoms UOPK
Bottoms - Conversion
Naphthenics
10 FCC Reactor
Field
Description
423
Field
Description
LCO UOPK
LCO - Conversion
Bottoms UOPK
Bottoms - Conversion
Aromatics
424
Field
Description
10 FCC Reactor
Field
Description
LCO UOPK
LCO - Conversion
Bottoms UOPK
Bottoms - Conversion
Cloud Point
Field
Description
RON
10 FCC Reactor
Field
Description
425
MON
Field
Description
If any variable attributes have been changed, their Modified entry becomes
checked. To sort by Modified, double-click the Modified column header.
Results Tab
Viewing Feed Blend Results
The Feed Blend page on the Results tab of the FCC Reactor Section property
view displays the detailed characterization of each individual feed and the blend
of feeds going to each riser location.
If there are two risers, or there is a feed mid-point injection, you can use the
Blend Properties at Selected Riser Location list to choose the location to
display.
426
10 FCC Reactor
Note:Use this page to view results of a simulation run. A simulation run is a simple
what-if study. It shows which changes to dependent variables result from a specified set
of independent variables.
To see the Feed Blend results for a calibration run, use the Feed Blend page on the Analysis tab of the Calibration property view. A calibration run fits the models kinetic rate constants and base operating data to match an observed process operation, feed properties,
and product yields. This is also called a tuning run.
Each feed and recycle stream is displayed in a column. The last column displays
the total feed blend.
Blend Properties
l
Bulk properties
l
API Gravity
Ramsbottom
Carbon
Residue
RI @Specified T Meas
l
l
Viscosity, SUS@210F
Lab
Viscosity CSt@210F
Est.
Vanadium content
[ppmwt]
Nickel content
[ppmwt]
Sodium content
[ppmwt]
Iron content
[ppmwt]
Copper content
[ppmwt]
D1160 VABP
K Factor based on
D1160 VAPB
K Factor based on
D2887 50% point
Hydrogen content
Molecular weight
RI Meas. Temperature
RI @20C
Calc. from
Lab Data
Viscosity CSt@210F
Lab
% of blended fresh
feed aromatics in
each feed
% of blended fresh
feed H in each feed
RI @20C est.
from Bulk.
Prop
Ca Meas
10 FCC Reactor
Ca Est. from
Total Method
427
Blend Properties
Distribution data
428
D2887 Initial
point
TBP 5% point
D2887 50%
point
TBP Endpoint
D2887 70%
point
D86 5% point
D86 Endpoint
D2887 5%
point
D2887 10%
point
D2887 30%
point
D2887 90%
point
D2887 95%
point
D2887 Endpoint
D1160 Initial
point
D1160 5%
point
D1160 10%
point
D1160 30%
point
D1160 50%
point
D1160 70%
point
D1160 90%
point
D1160 95%
point
D1160 Endpoint
10 FCC Reactor
Blend Properties
Base Kinetic Lump composition
l
l
l
10 FCC Reactor
C1-C4 lump
C5-430 lump
650-950 One-ring
aromatics
650-950 Two-ring
aromatics
430-650
Paraffins
430-650
Naphthenes
950+ Paraffins
950+ Naphthenes
430-650
One-ring aromatics
430-650
Two-ring aromatics
650-950
Paraffins
650-950
Naphthenes
650-950 Aromatic sidechains
429
Blend Properties
Adjusted Kinetic Lump Composition Detail
l
l
l
650-950 Two-ring
aromatics
650-950 Three+ ring
aromatics
430-650
Paraffins
430-650
Naphthenes
950+ Paraffins
950+ Naphthenes
Totals
650-950
Paraffins
650-950
Naphthenes
650-950 Aromatic sidechains
650-950
One-ring aromatics
C1-C4 lump
650-950 lump
C5-430 lump
950+ lump
Totals
C1-C4 lump
One-ring aromatics
C5-430 lump
Two-ring aromatics
Paraffins
l
l
l
l
l
430
C5-430 lump
C1-C4 lump
430-650
lump
Naphthenes
Aromatic sidechains
Aromatic sidechains
Totals
10 FCC Reactor
Blend Properties
Composition For Flash Calculations
Pseudo250
Pseudo610
Pseudo280
Pseudo640
Pseudo310
Pseudo670
Pseudo340
Pseudo700
Pseudo370
Pseudo750
Pseudo400
Pseudo800
Pseudo430
Pseudo850
Pseudo460
Pseudo900
Pseudo490
Pseudo950
Pseudo520
Pseudo1050
Pseudo550
Pseudo1150
Pseudo580
Pseudo1250
Pseudo2000
You can select from two options for how the product yields are displayed:
l
Volume Flow
H2S
Mass Flow
Fuel Gas
Volume %
Propane
Weight %
Propylene
LCO
n-Butane
Bottoms
i-Butane
Coke
10 FCC Reactor
Butenes
C5+ Naphtha
Total Conversion
431
Volume Flow
H2S
Cyclopentane
Mass Flow
Hydrogen
3m1-Butene
Volume %
Methane
1-Pentene
Weight %
Ethane
2m1-Butene
Ethylene
c2-Pentene
Propane
t2-Pentene
Propylene
2m2-Butene
n-Butane
Cyclopentene
i-Butane
Isoprene
1-Butene
Benzene
c2-Butene
C5+ Naphtha
t2-Butene
LCO
Butadene
Bottoms
n-Pentane
Coke
i-Pentane
Total Conversion
432
10 FCC Reactor
Dewpoint temperature
Mix temperature
Mix pressure
Total
Riser
Riser
Riser (kg)
10 FCC Reactor
433
Dewpoint temperature
Mix temperature
Mix pressure
Total
Riser bottom
Riser top
Total riser
Riser bottom
Riser top
Total riser
Note: In addition, the Total Catalyst Inventory (Risers and Reactor) amount in kilograms is reported.
434
10 FCC Reactor
Cyclone Temperature
Flue Gas O2
Flue Gas CO
O2 Injection Temperature
Catalyst Inventory
Mass Flows
Volume Flows
10 FCC Reactor
435
Temperatures
Pressures
Enrich O2 temperature
Enrich O2 pressure
Wet Air N2
Wet Air O2
Enriched Air N2
Enriched Air O2
Enriched Air CO
Standard Volume
Conditions
436
10 FCC Reactor
Cat/Oil Ratio
Note: Use this page to view results of a simulation run. A simulation run is a simple
what-if study. It shows which changes to dependent variables result from a specified set
of independent variables.
To see the Heat Balance results for a calibration run, use the Heat Balance page on the
Analysis tab of the Calibration property view. A calibration run fits the models kinetic
rate constants and base operating data to match an observed process operation, feed properties, and product yields. This is also called a tuning run.
Advanced Page
The Advanced page on the Results tab of FCC Reactor Section property view
displays miscellaneous results, such as sulfur balance and coke distribution.
The Sulfur Distribution group displays:
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10 FCC Reactor
437
Specification Wizard
When you click the Run Predictions of Calibration button, HYSYS lets you
select a calibration factor set, and select the data set you want to use for the
prediction calculation.
Note: The Run Predictions of Calibration button is unavailable until all necessary
input is complete.
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The Select Data Sets for Prediction view displays status and names
of data sets available with the calibration run.
Object
Description
Select Calibration
Factor Set to Use for
Prediction drop-down
list
Library button
Stop button
Close button
Select the appropriate check box under the Include column to select the
data set you want to use in the prediction calculation. When you select
the check box, the Specification Wizard view of the selected data set
appears.
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10 FCC Reactor
The Specification Wizard property view enables you to select the variable(s) that is specified for the prediction calculation, the rest of the variables will be calculated.
1. In the Regenerator group, select the appropriate check box of the variable you want the prediction calculation to accept the specified value,
while the rest of the variables are calculated based on the specified
value.
2. If a fractionator is included in the FCC, then the TBP cut point specs
appears in the Specification Wizard view. You can modify the values in
the Specify TBP Cut Points group and the new data will be used in the
prediction run.
3. Click the OK button to close the Specification Wizard view and accept the
modification/selections.
4. Click the Cancel button to close the Specification Wizard view and not
accept the modification/selections.
FCCValidation Wizard
When you click the Run Calibration button, HYSYS lets you select the data set
you want to use for the calibration run, and validate the selected data set
before the calibration is actually run.
Note: The Run Calibration button in the Calibration view is unavailable until all necessary calibration input is complete.
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439
The Select Data Sets for Calibration view displays status and names
of data sets available with the calibration run.
This view will appear only when there is more than one data set. If
theres only one data set, Validation Wizard view will appear instead.
Button
Description
Run Calibration
Enables you to run the calibration using the selected data set in
the Select Data Sets for Calibration group.
This button is not active until you have selected and validated a
data set.
Stop
Close
Enables you to close the Select Data Sets for Calibration view
without performing any calibration run.
Select the appropriate check box under the Include column to select the
data set you want to use in the calibration run. When you select the
check box, the Validation Wizard view of the selected data set appears.
l
The Validation Wizard property view displays the mass flows of feed and
product streams (derived from the input data), and coke flow and wt%
hydrogen in coke (calculated using air rate and flue gas analysis).
The information displayed enables you to analyze the measurement data
before accepting the data set for the calibration run. The coke mass flow
and hydrogen in coke are also calculated from flue gas analysis. Any
unreasonable values indicate that the flue gas analysis is questionable
and you should not proceed with the calibration.
If the total product mass rate is greater than the total feed mass rate by about
2-3%, you should review the flow rate and gravity information of the products.
If you think the error is acceptable, you can decide how you would like to distribute the mass imbalance by assigning the bias to any of the product streams
(except coke). Once the bias is assigned, the Validation Wizard adjusts the
mass flow of the selected product stream(s) to match the feed total mass flow
by re-normalization.
If the coke flow and wt% hydrogen in coke values are not reasonable, the air
rate measurement and flue gas analysis should be reviewed before calibration
is run.
In the Coke and Sulfur Balance group, you must specify the following values
for the calibration of coke and sulfur balance:
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10 FCC Reactor
When all the information in the Validation Wizard view appears satisfactory,
click the OK button to accept the values in the selected data set. The Validation
Wizard view closes and you return to the Select Data Sets for Calibration view.
Note: You can click the Cancel button to close the Validation Wizard view without saving/accepting any changes made in the view.
Once the data set has been selected and validated, you can click the Run Calibration button on the Select Data Sets for Calibration view to start the calibration run.
Note: The Validation Wizard does not display recycle streams.
Route 1
1. Configure the FCC using the Configuration Wizard.
2. On Page 4 of the Configuration Wizard, select the Use an existing set
of calibration factors option.
3. Enter the data and perform a simulation run using default (or any previously saved) calibration factor set. A simulation run is a simple
what-if study. It shows which changes to dependent variables result
from a specified set of independent variables.
4. Open the Calibration property view by selecting Calibration from the
FCC menu.
5. Click Pull Data From Simulation to copy data from the property views
in the FCC environment to the Calibration property view.
6. Enter additional observed or measured data from the FCC.
7. Perform a calibration run. A calibration run fits the models kinetic rate
constants and base operating data to match an observed process operation, feed properties, and product yields. This is also called a tuning
run.
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441
Route 2
1. Configure the FCC using the Configuration Wizard.
2. On Page 4 of the Configuration Wizard, select Calibrate the model to
produce a new set of calibration factors option.
3. In the Calibration property view, enter all observed or measured data
from the FCC.
4. Perform a calibration run. A calibration run fits the models kinetic rate
constants and base operating data to match an observed process operation, feed properties, and product yields. This is also called a tuning
run.
5. After a calibration run, you can click Push Data to Simulation to copy
data from the Calibration property view to the FCC environment property
views for use in other simulations.
Whichever method you use to calibrate an FCC, after you have performed the
calibration run, you can save the newly generated Calibration Factor set for
use in simulation, or export it to be used in other cases.
To push the data generated by the calibration run into the simulation property
view:
1. On the Calibration property view, click Push Data to Simulation.
HYSYS warns you that the Simulation data will be overwritten with the
current Calibration data.
2. Click OK to push the Calibration data into the Simulation property view.
HYSYS confirms that the data was copied successfully.
3. Click OK.
To pull the data from the simulation into the calibration property view:
1. On the Calibration property view, click Pull Data from Simulation.
HYSYS warns you that the Calibration data will be overwritten with the
current Simulation data.
2. Click OK to pull the Simulation data into the Calibration property view.
HYSYS confirms that the data was copied successfully.
3. Click OK.
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10 FCC Reactor
3. Click OK to push the calibration data into the FCC property view.
HYSYS confirms that the data was copied successfully.
4. On the Save Calibration Factor Set dialog, specify whether this Calibration Factor set should be used for the current simulation or not. The
default is Yes.
5. In the Set Name field, enter the name for this Calibration Factor set.
6. Do one of the following:
o
Click Save to save this Calibration Factor set and exit the Save
Calibration Factor Set dialog.
Note: Closing the Calibration property view does not save the calibration factor set.
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If the Calibration property view contains only one data set, the
Specification Wizard property view appears. Skip to step 4.
2. In the Select Data Sets for Prediction property view, select the calibration factor set for the prediction run using the Select Calibration
Factor Set to Use for Prediction drop-down list.
Tip:Click the Library button to access the Calibration Set Library view and manipulate the available calibration factor sets.
3. In the Select Data Sets for Prediction group, under the Include
column, select the check box of the data set you want to use for the prediction run.
Tip:To perform multiple case predictions, select the check boxes of the other data
sets.
4. In the Specification Wizard view, select the check boxes of the variables you want to be specified.
5. Click the OK button.
6. Click the Run Prediction button on the Select Data Sets for Prediction property view.
Tips:
o
Click the Stop button to stop the prediction run during calculation.
Click the Close button to close the Select Data Sets for Prediction
property view.
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To select multiple data sets for a prediction run, in the Select Data
Sets for Prediction table, select the check box associated to the data
set you want to use under the Include column.
To select the calibration factor set for the prediction run, open the dropdown list in the Select Calibration Factor Set to Use for Prediction
field and select the calibration factor set you want to use.
To run the prediction calculation, select the calibration factor you want,
select the data sets you want, select the variables you want specified,
and click the Run Prediction button.
445
Tips:
o
If the data set is not ready for the prediction run (for example, the
status displays Input Incomplete), the check box beside the data set
is inactive.
The Run Prediction button is inactive until you select a data set for
the prediction run.
Click the Stop button to stop the prediction run during mid-calculation.
Click the Close button to exit the Select Data Sets for Prediction property view.
If the Calibration property view contains only one data set, the
Validation Wizard property view appears. Skip to step 3.
2. In the Select Data Sets for Calibration property view, under the Include
column, select the check box of the data set you want to use for the calibration run.
Tip:To perform multiple case calibrations, select the check boxes of the other
data sets.
3. In the Validation Wizard property view, make sure the data set is ready
for the calibration run then close the Validation Wizard property view.
4. Click the Run Calibration button in the Select Data Sets for Calibration
property view.
Tips:
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Click the Stop button to stop the calibration run during calculation.
Click the Close button to close the Select Data Sets for Calibration property view.
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To select multiple data sets for a calibration run, in the Select Data
Sets for Calibration table, select the check box associated to the data
set you want to use under the Include column.
To run the calibration, select the data sets you want to use in the calibration run, validate the selected data sets, and click the Run Calibration button.
Tips:
o
If the data set is not ready for the calibration run (for example, the
status displays Input Incomplete), the check box beside the data set
is inactive.
The Run Calibration button is inactive until you select a data set for
the calibration run.
Click the Stop button to stop the calibration run during mid-calculation.
Click the Close button to exit the Select Data Sets for Calibration property view.
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447
ulation, check the Use this set for the current simulation option;
otherwise clear this option.
Save the calculated Calibration Factors for use in the FCC environment.
Push data from a calibration run to the property view in the FCC environment.
Pull data from a simulation run to the Calibration property view. A simulation run is a simple what-if study. It shows which changes to
dependent variables result from a specified set of independent variables.
448
Button
Description
Enables you to select one or more data set for the calibration run and
access the ValidationWizard property view.
Manage
Data Sets
Enables you to access the Data Set Manager Property View to manage
the data set.
Push Data
to Simulation
Enables you to export input data from the current data set in the calibration property view to the property view in the FCC environment.
Pull Data
from Simulation
Enables you to import input data from the property view in the FCC
environment into the current data set in the Calibration property view.
Return to
Simulation
Enables you to exit the Calibration environment and return to the FCC
environment.
Any existing simulation data will be overwritten with the current calibration data.
Any existing calibration data will be overwritten with the current simulation data.
10 FCC Reactor
Note:At the bottom of the theFCCCalibration property view, from the Data Set dropdown list, you can select different data sets for entering the data or viewing the results for
the calibration or the prediction run.
The status bar displays the current status of the calibration run.
The pages of the Calibration property view are identical to those of the FCC
Reactor Section property view, but they contain different data. The key difference is that FCC Reactor Section property view displays and allows input of
the variables for a simulation run, and the Calibration property view displays
and allows input of the variables for a calibration run.
To exit the Calibration environment and return to the HYSYS simulation environment (FCC environment), click the Return to Simulation button on the
CatCracker ribbon tab.
Configuring Calibration
Use the Design tab on the Calibration property view to view specific information about the FCC unit you are modeling. This information is used in a calibration run. A calibration run fits the models kinetic rate constants and base
operating data to match an observed process operation, feed properties, and
product yields. This is also called a tuning run.
You use the Design tab to view the following types of information about the
FCC:
Use this page
to
Configuration
Geometry
Risers
Strippers
Regenerators
Heat Loss
Notes
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449
Risers
Strippers
Regenerators
Note: If you selected the Allow Midpoint Injection option on the Configuration Wizard
Configuration Page (page 1), HYSYS displays the Injection Point in the Riser group.
Tip:To change geometry specifications, click Configuration Wizard to access the Configuration Wizard.
The physical length, diameter, and height of the key reactor and regenerator
equipment are defined in this page.
Riser Group
The Riser group is made up of two fields, as described below:
Field
Description
Total Length
Diameter
Description
Total Length
Injection Point
Use average inner diameter for the riser diameter input. In the case with midpoint injection, the injection point is measured from the bottom of the riser.
The length and diameter of the riser termination zone is dependent upon the
desired residence time of the vapors leaving the tip of the riser and the entry of
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10 FCC Reactor
the secondary reactor cyclones. You could enter the actual diameter of the
reactor for the diameter field, and vary the length until the residence time
matches acceptable results.
Description
Length
Diameter
Stripper Group
The Stripper group is made up of three fields, as described below:
Field
Description
Height
Diameter
Annulus Diameter
The stripper diameter is the entire internal diameter of the reactor stripper
model. The annulus diameter is the riser inner diameter in the stripper section,
plus the corresponding layers of refractory in the stripper, metal thickness of
the riser, and refractory thickness in the riser. If the FCC design has an
external riser, the annulus diameter is zero.
Regenerator Group
The Regenerator group is made up of seven fields, as described below:
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Field
Description
Interface Diameter
Cyclone Inlet
Height
The height of the Regenerators Cyclone inlet above the regenerators bottom.
451
Field
Description
The regenerator bed height is adjusted to get the correct cat inventory number
in the regenerator. The interfacial diameter is normally set equal to the regenerator bed diameter. The height of the inlet of the regenerator cyclone is equal
to the length from the first stage cyclone inlet to the air grid. The equipment layout is based on the typical side-by-side FCCU design.
Tip:To change heat loss specifications, you can also access the Configuration Wizard.
452
Use this
page
To
Library
Properties
Specify properties for virtual feeds, which is to say feeds that are
not represented by an internal and external stream in the subflowsheet and flowsheet respectively.
10 FCC Reactor
By default, data of a VGO feed are filled in when you add a Feed Type. A library
of Feed Types containing multiple Feed Types is provided in the
FCC/FeedLibrary subfolder of your installation folder. You can import one or
more of them to your simulation.
Assay
Note:If the feed is a real stream, then the Assay option is selected,
and you cannot change it. You can change the feed name and the feed
type, but not the assay name. The top and bottom cut points will not be
shown at all.
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Bulk Properties
Kinetic Lumps
453
The FCC model uses these feed properties and the specified Feed Type
to generate kinetic lumps of the feed for the simulation.
When you select a feed in the list box, the rest of the form is filled out
with the data for the selected feed. If the feed is a real stream, then you
cannot choose a property method. You can change only the feed name
and the feed type.
If you clone a riser feed which is mapped to an external stream, HYSYS
copies the calculated bulk properties from the stream and uses them as
the input bulk properties for the new feed.
Tips:
o
To create a new virtual feed and initialize it with the data from the selected feed, click Clone.
Even if the selected feed is a real stream, the clone/copy is flagged as a
virtual feed.
3. In the Properties of Selected Feed table, you can view and edit properties. The type of stream properties available for modification depends
on the method you select in the Feed Properties group. If you select the:
If you selected the Assay radio button:
The bulk properties calculated from the assay and the cut points are displayed.
Field
Description
Name
Feed
Type
The feed type. Select the feed type from the drop-down list. The
feed types available are those in the Available Feed Types list on
the Library page of the Feed Data tab.
Assay
Name
Top Cut
Point
(optional)
Bottom
Cut Point
(optional)
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Field
Description
Name
Feed Type
The feed type. Select the feed type from the drop-down list. The
feed types available are those in the Available Feed Types list
on the Library page of the Feed Data tab.
API Gravity
Specific Gravity
Distillation
type
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TBP
D86
D1160
D2887
Initial Point
5% Point
10% Point
30% Point
50% Point
70% Point
90% Point
95% Point
Endpoint
Basic Nitrogen
Total Nitrogen
Total/Basic
Nitrogen
Ratio
Sulfur Content
Fraction of
Feed S Processed
Conradson
Carbon
Residue
455
Field
Description
Ramsbottom
Carbon
Residue
RI @Specified T Meas.
(Optional)
RI Meas.
Temperature
(Optional)
RI @20C
Calc. from
Lab Data
RI @20C
Est. from
Bulk Prop.
Ca Meas.
(Optional)
Ca Est. from
Total Method
Viscosity,
cSt@210F
Lab.
(Optional)
Viscosity,
SUS@210F
Lab.
(Optional)
Viscosity,
cSt@210F
Est.
Vanadium
Nickel
Sodium
Iron
Copper
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10 FCC Reactor
Field
Description
Name
Feed Type
The feed type. Select the feed type from the drop-down list. The
feed types available are those in the Available Feed Types list
on the Library page of the Feed Data tab.
C1-C4 Lump
C5-430
Lump
430-650
Paraffins
430-650
Naphthenes
430-650
Two ring Aromatics
650-950
Paraffins
650-950
Naphthenes
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650-950
One ring Aromatics
650-950
Two ring Aromatics
650-950
Three+ ring
Aromatics
950+
Paraffins
457
Field
Description
950+ Naphthenes
950+ One
ring Aromatics
950+ Two
ring Aromatics
950+
Three+ ring
Aromatics
API Gravity
Distillation
type
458
TBP
D86
D1160
D2887
Initial Point
5% Point
10% Point
30% Point
50% Point
70% Point
90% Point
95% Point
Endpoint
Basic Nitrogen
Total Nitrogen
Total/Basic
Nitrogen
Ratio
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Field
Description
Sulfur Content
Fraction of
Feed S Processed
Conradson
Carbon
Residue
Ramsbottom
Carbon
Residue
Vanadium
Nickel
Sodium
Iron
Copper
Configuring Catalysts
Use the Catalyst tab on the Calibration property view to:
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l
Work with Catalysts using the Catalyst libraries on the Library page.
View and specify calibration information about the catalyst blend on the
Blend page.
View and specify calibration information about the catalyst metals on the
Activity page.
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459
Object
Description
Available
Catalysts
list
Edit button
Add button
Delete
button
Clone
button
Enables you to clone the selected catalysts in the Available Catalysts list.
Import
button
Enables you to import a catalyst from a separate file into the FCC operation.
Export
button
The exported catalyst in the file can be imported into a different FCC operation.
Specify the weight fraction of each catalyst in the blend when you have
multiple catalysts.
Note: To view and edit the details of the blend, click Blend Details.
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l
Each feed and recycle stream is displayed in a column. The last column displays
the total feed blend.
Use the Base Catalyst Blend and Composition group to specify details
about the base catalyst blend. The objects are described below.
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10 FCC Reactor
Object
Description
Weight
Fraction
row
Zeolite
row
The calculated amount of Zeolite in the catalyst. You can override the
amount of Zeolite in the catalyst.
Alumina
row
The calculated amount of Alumina in the catalyst. You can override the
amount of Alumina in the catalyst.
Rare
Earth row
The calculated amount of Rare Earth in the catalyst. You can override the
amount of Rare Earth in the catalyst.
Normalize
button
Enables you to normalize the weight fractions of all the catalyst so that the
sum equals 1.
Blend
Details
button
Enables you to access the FCC Catalyst: Catalyst Blend view of the selected catalyst in the Base Catalyst Blend and Composition table.
Export
Blend button
The FCC Catalyst: Catalyst Blend View enables you to modify detail blend
information of the selected catalyst.
Note: The Base Catalyst Blend is always calculated using the normalized weight fraction of the catalysts.
The ZSM-5 Additive group contains two fields, which are described below:
Field
Description
Selectivity
ZSM-5 per
Unit Mass
of Base
Blend
High Selectivity
The amount of ZSM-5 Additive per Unit Mass of the Base Blend. Note: The
ZSM-5 per Unit Mass of Base Blend is the fraction of ZSM-5 zeolite crystal
in the total blend (and not the fraction of total additive in the total blend).
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Field
Description
461
Description
Vanadium
Nickel
Sodium
Iron
Copper
The Feed Metal Totals and Biases group displays the following information
for metal totals and biases:
462
Row
Description
Vanadium
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Row
Description
Nickel
Sodium
Iron
Copper
The Equilibrium Catalyst group contains options that enable you to specify
the ppmwt for each of the ECAT metals, fresh make up rate, and MAT activity:
Cell
Description
Vanadium
Nickel
Sodium
Iron
Copper
Note: The metals in equilibrium catalyst include the amounts from both the feed and the
base catalyst.
OperationTab
Specifying Feed Streams for Calibration/Prediction
Use the Feeds page on the Operation tab of the Calibration property view to
view and specific physical information about feeds.
This data is used for calibration runs. A calibration run fits the models kinetic
rate constants and base operating data to match an observed process operation, feed properties, and product yields. This is also called a tuning run.
In the Feed Conditions group, for each feed, you can specify or view:
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Volume flow
Mass flow
Temperature
Pressure
463
For the Total Feed and Dispersion Steam group, at each feed location, you
can view:
Field
Description
Fresh Feed
Volume
Total Feed
Volume
The volume flow rate of the total feed (fresh feed + recycle) at this
location.
The mass flow rate of the total feed (fresh feed + recycle) at this location.
Or specify or view:
Field
Description
Steam Volume
Steam Mass
Steam Pressure
Steam Temperature
464
Field
Description
Catalyst/Oil Ratio
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If the FCC has two risers, the Riser Temperature Control group contains
eight fields, which are described below:
Field
Description
The Riser1-Riser 2
Bias
Temperature difference between Riser 1 and Riser 2 outlet temperatures (Riser 1 Riser 2).
Riser1 Catalyst/Oil
Ratio
Riser2 Catalyst/Oil
Ratio
The Reactor Stripping Zone group contains four fields, which are described
below:
Field
Description
Stripping steam mass flow rate per thousand of catalyst circulation rate.
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465
Regenerator
Description
Cyclone Temperature
Enrich O2 Temperature
Enrich O2 temperature.
Catalyst Inventory
Note: If you specified a two-stage regenerator, you specify the following information for
Stage 1 and Stage 2.
The Ambient Air Conditions group contains three fields, which are described
below:
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Field
Description
Temperature
Pressure
Relative Humidity
If you specified a two-stage Regenerator for the FCC, the Stage 1 Conditions
group appears. This group contains the following tables:
Dense Bed Temperature table
Row
Description
Apparent
Bias
CRC table
Row
Description
Apparent
Bias
Note: The apparent dense bed temperature and CRC are primarily used in the calibration.
They are treated as part of the measurements for the first stage regenerator. The difference between the apparent and the calculated values is the indication of the quality of
the data. If the quality of the data is good, the apparent value should be close to the calculated one.
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Field
Description
Reactor Pressure
467
Field
Description
Regenerator Pressure
The pressure difference between the top of the regenerator and the reactor.
The pressure difference between the bottom of the regenerator and the bottom of the riser.
If the FCC has one riser and a two-stage regenerator, the Pressure Control
group contains five fields, which are described below:
Field
Description
Reactor Pressure
If the FCC has two risers, the Pressure Control group contains five fields,
which are described below:
Field
Description
Reactor Pressure
Regenerator Pressure
The pressure difference between the top of the regenerator and the reactor.
The pressure difference between the bottom of the regenerator and the bottom of Riser 1.
The pressure difference between the bottom of the regenerator and the bottom of Riser 2.
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10 FCC Reactor
Feed temperature
These specifications are used in calibration runs. A calibration run fits the
models kinetic rate constants and base operating data to match an observed
process operation, feed properties, and product yields. This is also called a tuning run.
Note: The Fractionator page appears only when a fractionator is included in the FCC configuration.
Reboiler Duty
Steam Flow
Steam Pressure
Steam Temperature
The names and numbers of the streams vary depending on your specifications on the Design tab.
If the energy source for the zone is Reboiler in the fractionator configuration, you must specify the reboiler duty for that zone. If the energy
source for the zone is Steam Stripped, you must specify the steam flow,
pressure, and temperature for that zone.
Description
Maximum Iterations
Minimum Iterations
4. In the Creep Step Parameters group, specify the following fields. Use
this group to specify details about how the creep function of the DMO
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469
Description
On / Off
Switch
Iterations
Step Size
Description
Normal
(Default)
Hessian initialized with identity matrix. This setting balances efficiency and robustness. It is well suited for general purpose optimization problems. Typical applications are offline optimization and
online problems that start very far from a solution.
Aggressive
Hessian initialized with small values. This setting moves the problem to bounds faster than the Normal mode. This setting is preferred for highly constrained optimization problems with few
Degrees of Freedom at solution. Ideal applications are well-posed
online real-time optimization problems.
Scaled
A combination of the Aggressive and Advanced modes. Recommended for highly constrained optimization problems with few
Degrees of Freedom at solution and a nonlinear objective function.
Advanced
nd
7. In the Scaling factor field, specify the scaling factor to apply to the Hessian.
8. In the Updates stored field, specify the number of updates stored. The
default is 10.
9. In the Line Search Parameters group:
o
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10 FCC Reactor
Option
Description
Normal
(Default)
Exact
A well-known exact penalty line search. It is too conservative for most practical problems.
Residual
A proprietary line search designed to initially favor the convergence of residuals over the objective function improvement.
Square
Description
Normal
(Default)
Aggressive
Conservative
10. In the Variable Scaling Parameter group, from the On/Off Switch
drop-down list:
o
11. The Failure Recovery Action group contains a drop-down list that
enables you to select what the DMO Solver should do in the case of failure. The choices are:
o
Do nothing
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
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471
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
Description
Enables you to enter the text code for a command for the
solver.
Enables you to retrieve a previous command from the command history and place the text code in the Enter Script
Command field.
Enables you to retrieve the next command from the command history and place the text code in the Enter Script
Command field.
To clear the messages in the Simulation Engine Message and Script Commands field:
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Description
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473
Field
Description
Conversion
of H2 to C2
yields to
liquid
volume basis
Coke Distribution
Fraction Concarbon to
coke
Non-vaporized feed to
coke
Mass ratio of
H2 to metals
coke
Gasoline Overcracking
Pre-exponential
factor for
Gasoline
Cracking
Natural log of the pre-exponential factor for first order reaction rate for
naphtha cracking to gas lump.
Ea/R for
Gasoline
Cracking
474
Riser/reactor
term
Catalyst
stripper term
Riser/rxtr
term on
regen bed
side
Heat released by adsorption and desorption of kinetic coke on the catalyst in regenerator dense bed.
10 FCC Reactor
Field
Description
Catalyst
stripper term
on regen bed
side
Regen dilute
phase term
Catalyst split factor around reactor dilute phase. Fraction of total cat circ
that bypasses reactor dilute phase directly to the stripper.
10 FCC Reactor
Natural log of the pre-exponential factor for the first order cracking of
light paraffin (L-P) to light gases (C-lump).
Distillate
naphthenic
cracking to C
lump
Natural log of the pre-exponential factor for the first order cracking of
light naphthenic (L-N) to light gases (C-lump).
Natural log of the pre-exponential factor for the first order cracking of
light aromatic sidechains (L-As) to light gases (C-lump).
Natural log of the pre-exponential factor for the first order cracking of
light paraffin (L-P) to gasoline (G-lump).
Distillate
naphthenic
cracking to G
lump
Natural log of the pre-exponential factor for the first order cracking of
light naphthenic (L-N) to gasoline (G-lump).
Natural log of the pre-exponential factor for the first order cracking of
light aromatic sidechains (L-As) to gasoline (G-lump).
Natural log of the pre-exponential factor for the first order cracking of
light aromatic cores (L-As) to gasoline (G-lump).
475
Field
Description
Natural log of the bias between the cracking of resid to Light (430-650)
and Heavy (650-950) components. A value of zero means that a resid
cracks 50/50 to light and heavy. A value of .693 (ln 2) would mean that
resid cracks twice as fast to light compared to heavy.
476
Methane
from feed
light paraffin
Methane
from feed
light naphthenics
Methane
from feed
light aromatic sidechains
Methane
from feed
heavy paraffin
Methane
from feed
heavy naphthenics
Methane
from feed
heavy aromatic sidechains
Methane
from feed
resid paraffin
Methane
from feed
resid naphthenics
Methane
from feed
resid aromatic sidechains
10 FCC Reactor
Field
Description
Ethane from
Parameter that changes the response of ethane generated from light
feed light par- paraffin cracking.
affin
Ethane from
feed light
naphthenics
Ethane from
Parameter that changes the response of ethane generated light arofeed light aro- matic sidechain cracking.
matic sidechains
10 FCC Reactor
Ethane from
feed heavy
paraffin
Ethane from
feed heavy
naphthenics
Ethane from
feed heavy
aromatic
sidechains
Ethane from
feed resid
paraffin
Ethane from
feed resid
naphthenics
Ethane from
feed resid
aromatic
sidechains
Ethylene
from feed
light paraffin
Ethylene
from feed
light naphthenics
Ethylene
from feed
light aromatic sidechains
Parameter that changes the response of ethylene generated light aromatic sidechain cracking.
477
478
Field
Description
Ethylene
from feed
light 1-ring
aromatic
cores
Ethylene
from feed
light 2-ring
aromatic
cores
Ethylene
from feed
heavy paraffin
Ethylene
from feed
heavy naphthenics
Ethylene
from feed
heavy aromatic sidechains
Ethylene
from feed
heavy 1-ring
aromatic
cores
Ethylene
from feed
heavy 2-ring
aromatic
cores
Ethylene
from feed
heavy 3-ring
aromatic
cores
Ethylene
from feed
resid paraffin
10 FCC Reactor
Field
Description
Ethylene
from feed
resid naphthenics
Ethylene
from feed
resid aromatic sidechains
Ethylene
from feed
resid 1-ring
aromatic
cores
Ethylene
from feed
resid 2-ring
aromatic
cores
Ethylene
from feed
resid 3-ring
aromatic
cores
Thermal Cracking
10 FCC Reactor
Entry zone
cracking
activity
Entry zone
EA over RT
(1000F)
Post riser
cracking
activity
Post riser EA
over RT
(1000F)
Activation energy of the thermal cracking reaction at the post riser section.
Light Gas
Delumping
to Hydrogen
479
Field
Description
Light Gas
Delumping
to Ethane
Light Gas
Delumping
to Ethylene
Light Gas
Delumping
to Propane
Light Gas
Delumping
to Propylene
Light Gas
Delumping
to i-Butane
Light Gas
Delumping
to n-Butane
Light Gas
Delumping
to Butylenes
CRCResponse
CRC
Response
Intercept
CRC
Response
Slope
MAT Tuning
480
Catalyst
Activity vs.
Cracking
Factor
Catalyst
Activity vs.
Coking
Factor
10 FCC Reactor
Sulfur
10 FCC Reactor
Field
Description
LCO - Conversion
Bottoms - Conversion
481
Gravity
Field
Description
LCO UOPK
LCO - Conversion
Bottoms UOPK
Bottoms - Conversion
Olefins
482
Field
Description
10 FCC Reactor
Field
Description
LCO UOPK
LCO - Conversion
Bottoms UOPK
Bottoms - Conversion
Naphthenics
10 FCC Reactor
Field
Description
483
Field
Description
LCO UOPK
LCO - Conversion
Bottoms UOPK
Bottoms - Conversion
Aromatics
484
Field
Description
10 FCC Reactor
Field
Description
LCO UOPK
LCO - Conversion
Bottoms UOPK
Bottoms - Conversion
Cloud Point
Field
Description
RON
10 FCC Reactor
Field
Description
485
MON
Field
Description
The analyses and cuts available vary depending on whether the FCC has a fractionator. If the FCC has a fractionator, the naphtha cuts, LCO cuts, and Bottom
cuts are those you specified on the Configuration Wizard.
486
10 FCC Reactor
Number/Options to Specify
Up to 5
Up to 4
Up to 3
Up to 2
Bottom cuts
Bottoms
-orHCO and Bottoms
Fuel Gases
LPGs
Naphthas
The matrix that appears for you to input measurement data is based on the cuts
specified on the Cuts page.
For example, the Heavy Naphtha column appears only if the configuration has
a Heavy Naphtha draw.
For each GC data type, you can enter the following measured parameter values:
l
l
When you enter a value for a flow rate or composition, the Input Composition
for GC Analysis dialog appears on which to enter the data. On this screen you
can normalize the compositions of every analysis.
Notes:
10 FCC Reactor
487
For each GC data type column, you can enter only one flow rate.
For example, in the Fuel Gas columns the Liquid Rate row is not available, and for the other columns the Gas Rate row is not available.
You only need to enter the Naphthenes, Olefins, and Aromatics data for
the naphtha cuts.
The FCC model adjusts the reference curve for Naphthenes, Olefins, and
Aromatics to match the measurements specified. The model then extrapolates the curves to the regions where you did not specify data.
Tips:
o
To clear all the values on the Input Composition for GC Analysis property
view, click Erase.
To normalize the values on the Input Composition for GC Analysis property view to 1, click Normalize.
488
10 FCC Reactor
Note:You only need to enter the Naphthenes, Olefins, and Aromatics data for the naphtha cuts. The FCC model adjusts the reference curve for Naphthenes, Olefins, and Aromatics to match the measurements specified. The model then extrapolates the curves to
the regions where you did not specify data.
You can input measured values for the following parameters for the flow rates
and composition.
Parameter
UOM
Mass Rate
MLB/HR
Volume Rate
MBBL/DAY
Distillation Type
TBP
D86
D1160
D2887
IBP
5%Point
10%Point
30%Point
50%Point
70%Point
90%Point
95%Point
End Point
API Gravity
Specific Gravity
Sulfur
WTPCT
RON
MON
10 FCC Reactor
Olefins
PONA Vol%
Naphthenics
PONA Vol%
Aromatics
PONA Vol%
Cloud Point
Concarbon
Wt%
Basic N
PPMW
489
The Reactor Group group displays the entire calculated reactor and (if
it exists) fractionator calibration factors.
Factors
1.378
0.5890
1.618
9.156e-005
490
5.449
3.675
5.658
2.798
10 FCC Reactor
Factors
7.867
4.220
2.536
2.712
0.8972
1.249
0.2401
0.2484
0.2111
8.744e-003
2.060e-002
3.470e-002
0.1203
2.373e-002
0.1530
0.2550
1.785e-002
3.311e-002
9.299e-003
10 FCC Reactor
0.3000
0.3000
0.3333
0.3000
0.3000
1.669e-013
6.995e-014
5.264e-013
-1.128e-012
2.621e-014
491
Factors
0.7987
-10.72
0.7987
Stripper parameter
2.357
0.8301
15.30
-1.001
10.99
1.348e-002
8.235e-002
1.871
The Delumping and Property Curves group displays the 53 rows corresponding to the 53 base hypo components used for every curve.
Note: The base hypo components used in delumping and properties curves are
fixed and different from those used in the assay.
o
The first column displays the normal boiling points of the base
hypo components.
The remaining columns display the property curves for the ten
properties whose curves are calculated during calibration.
These properties are:
o
o
o
o
Sulfur
Basic Nitrogen
Naphthenics
o
Aromatics
o
o
Cloud Point
RON
CCR
o
o
Gravity
MON
Olefins
From the Calibration Factors page you can perform the following actions as
well:
492
10 FCC Reactor
Accessing the Calibration Factor Set Library. To do this, click Calibration Factors Library.
In the normal workflow, after running the calibration and reviewing the results,
you will save the calculated calibration factors. Therefore, if you return to the
simulation environment without first saving or exporting the calibration factors,
the system prompts you with:
Do you want to make the newly calculated calibration factors available for simulation?
The options are:
If you select this
option
then
Yes
No
Cancel
10 FCC Reactor
493
The Export Calibration Factor Set dialog box appears when you click
Export on the Calibration Factors page of the Analysis tab of the Calibration property view.
To export and save the current Calibration Factor set:
1. On the Calibration Factors page of the Analysis tab of the Calibration
property view, click Export.
The Export Calibration Factor Set dialog appears.
2. On the Export Calibration Factor Set dialog do one of the following:
o
In the Set Name field, enter the name under which you want to
save this set of Calibration factors.
3. On the File selection for exporting Factor Sets dialog, click Save to
save the file.
Tip:Click Cancel to abandon the operation without saving the Calibration Factors
as a file.
494
10 FCC Reactor
Each feed and recycle stream is displayed in a column. The last column displays
the total feed blend.
The following information appears for each feed:
Blend Properties
Bulk properties
API Gravity
Viscosity CSt@210F
Lab
Viscosity, SUS@210F
Lab
Viscosity CSt@210F
Est.
Copper content
(ppmwt)
D1160 VABP
K Factor based on
D1160 VAPB
K Factor based on
D2887 50% point
Hydrogen content
Molecular weight
Total/Basic
Nitrogen
Ratio
Sulfur Content
Fraction of
Feed S Processed
Conradson
carbon
residue
Ramsbottom
carbon
residue
RI @Specified
T Meas
RI Meas. Temperature
RI @ 20C
Calc. from
Lab Data
RI @20C est.
from Bulk.
Prop
Ca Meas
l
10 FCC Reactor
Ca Est. from
Total Method
495
Blend Properties
Distribution data
D2887 Initial
point
D2887 5%
point
D2887 30%
point
D2887 50%
point
D2887 70%
point
496
D2887 10%
point
D2887 90%
point
D2887 95%
point
D2887 Endpoint
D1160 Initial
point
D1160 5%
point
D1160 10%
point
D1160 30%
point
D1160 50%
point
D1160 70%
point
D1160 90%
point
D1160 95%
point
D1160 Endpoint
TBP 5% point
TBP Endpoint
D86 5% point
D86 Endpoint
10 FCC Reactor
Blend Properties
Base Kinetic Lump composition
C1-C4 lump
C5-430 lump
950+ Paraffins
950+ Naphthenes
Totals
430-650
Paraffins
l
430-650
Naphthenes
10 FCC Reactor
430-650
One-ring aromatics
430-650
Two-ring aromatics
650-950
Paraffins
650-950
Naphthenes
497
Blend Properties
Adjusted Kinetic Lump Composition Detail
C1-C4 lump
C5-430 lump
950+ Paraffins
950+ Naphthenes
Totals
430-650
Paraffins
l
430-650
Naphthenes
430-650
Two-ring aromatics
650-950
Paraffins
650-950
Naphthenes
C1-C4 lump
650-950 lump
C5-430 lump
950+ lump
430-650
lump
Totals
C1-C4 lump
One-ring aromatics
C5-430 lump
Two-ring aromatics
Paraffins
Naphthenes
Aromatic sidechains
Aromatic sidechains
Totals
498
430-650
One-ring aromatics
10 FCC Reactor
Blend Properties
Composition For Flash Calculations
Pseudo250
Pseudo610
Pseudo280
Pseudo640
Pseudo310
Pseudo670
Pseudo340
Pseudo700
Pseudo370
Pseudo750
Pseudo400
Pseudo800
Pseudo430
Pseudo850
Pseudo460
Pseudo900
Pseudo490
Pseudo950
Pseudo520
Pseudo1050
Pseudo550
Pseudo1150
Pseudo580
Pseudo1250
Pseudo2000
Note:For the fractionated yields, the liquid product cuts correspond to those specified on
the Configuration Wizard.
10 FCC Reactor
Fractionated products
499
Note:For fractionated products, the product cuts are those you specified on the Configuration Wizard.
API Gravity
Specific Gravity
Sulfur [%]
RON
MON
(R+M)/2
Paraffins [vol %]
Olefins [vol %]
Naphthenes [vol %]
Aromatics [vol %]
Concarbon [%]
Paraffins [wt %]
Olefins [wt %]
Naphthenes [wt %]
Aromatics [wt %]
500
API Gravity
Specific Gravity
Sulfur [%]
RON
MON
(R+M)/2
Paraffins
Olefins
Naphthenes
Aromatics
Concarbon [%]
10 FCC Reactor
Dewpoint temperature
Mix temperature
Mix pressure
Total
Riser
Riser
Riser (kg)
10 FCC Reactor
501
Dewpoint temperature
Mix temperature
Mix pressure
Total
Riser bottom
Riser top
Total riser
Riser bottom
Riser top
Total riser
Riser bottom
Riser top
Total riser
502
10 FCC Reactor
Dewpoint temperature
Mix temperature
Mix pressure
Total
Riser
Riser
Riser (kg)
10 FCC Reactor
503
Mass Flows
Volume Flows
Temperatures
504
Enrich O2 temperature
10 FCC Reactor
Pressures
Enrich O2 pressure
Wet Air N2
Wet Air O2
Enriched Air N2
Enriched Air O2
Enriched Air CO
ECP
Top Index
Bottom Index
ECPOffset
The TBP Cut Points group displays the calculated cut point to match the specified flow rate of each zone.
10 FCC Reactor
505
Cat/Oil Ratio
Advanced Page
The Advanced page on the Analysis tab of the Calibration property view displays miscellaneous results such as sulfur balance and coke distribution from
the prediction run.
In the Distribution of Feed Sulfur in Products group:
506
10 FCC Reactor
10 FCC Reactor
507
Status
Regenerator data
Regenerator pressure
Regenerator temperature
Heat balance
Coke distribution
508
10 FCC Reactor
Note: Pages on the Prediction tab, except the Worksheet page, display the prediction
results of the current data set. You can select the current data set from the Data Set
drop-down list. If the prediction run has not been performed for the current set, only the
Worksheet page appears.
10 FCC Reactor
509
Coke Yield
For the riser (or Riser 1 and Riser 2 if the FCC has two
risers)
l
l
CRC %
510
10 FCC Reactor
10 FCC Reactor
Mole Flows
o
Mass Flows
o
Volume Flows
o
511
Temperatures
o
Pressures
o
512
10 FCC Reactor
l
l
Dewpoint temperature
Mix temperature
Mix pressure
Total
l
l
Riser
Reactor dilute phase
Riser
Riser (kg)
l
l
Dewpoint temperature
Mix temperature
Mix pressure
Total
Riser bottom
Riser top
l
l
Total riser
Reactor dilute phase
10 FCC Reactor
513
Riser bottom
Riser top
Total riser
Riser bottom
Riser top
Total riser
l
l
Dewpoint temperature
Mix temperature
Mix pressure
Total
l
l
Riser
Reactor dilute phase
Riser
Riser (kg)
514
10 FCC Reactor
API Gravity
Specific Gravity
Sulfur [%]
RON
MON
(R+M)/2
Paraffins [vol %]
Olefins [vol %]
Naphthenes [vol %]
Aromatics [vol %]
Concarbon [%]
Paraffins [wt %]
Olefins [wt %]
Naphthenes [wt %]
Aromatics [wt %]
If you select the Fractionated products radio button, the following values
appear for each stream listed:
10 FCC Reactor
API Gravity
Specific Gravity
Sulfur [%]
RON
MON
(R+M)/2
Paraffins [vol %]
Olefins [vol %]
Naphthenes [vol %]
Aromatics [vol %]
Concarbon [%]
515
Fractionated grouped
Fractionated detailed
If you select the Standard cut grouped radio button, the VolumeFlow,
Mass Flow, Volume, and Weight appear for each of the following variables:
l
H2S
Fuel Gas
Propane
Propylene
nButane
iButane
Butenes
Naphtha C5-430F
LCO 430-650F
Bottoms 650F+
Coke Yield
Total
Conversion
If you select the Standard cut detailed radio button, the VolumeFlow,
Mass Flow, Volume, and Weight appear for each of the following variables:
516
H2S
Hydrogen
Methane
Ethane
Ethylene
Propane
Propylene
n-Butane
i-Butane
i-Butene
1-Butene
c2-Butene
t2-Butene
Butadiene
10 FCC Reactor
n-Pentane
i-Pentane
Cyclopentane
3m1-Butene
1-Pentene
2m1-Butene
c2-Pentene
t2-Pentene
2m2-Butene
Cyclopentene
Isoprene
Benzene
Naphtha C6-430F
LCO 430-650F
Bottoms 650F+
Coke
Total
Conversion
H2S
Fuel Gas
C3 in LPG
C4 in LPG
C5 in LPG
Naphtha
LCO
Bottoms
Coke
Total
Conversion
10 FCC Reactor
H2S
Hydrogen
Methane
Ethane
Ethylene
Propane
Propylene
517
n-Butane
i-Butane
i-Butene
1-Butene
c2-Butene
t2-Butene
Butadiene
n-Pentane
i-Pentane
Cyclopentane
3m1-Butene
1-Pentene
2m1-Butene
c2-Pentene
t2-Pentene
2m2-Butene
Cyclopentene
Isoprene
C6+ in LPG
Naphtha
LCO
Bottoms
Coke
Total
Conversion
518
Open the FCC property view and click the FCC Environment
button to access the FCC environment.
10 FCC Reactor
Open the HCR property view and click the HCR Environment
button to access the HCR environment.
Open the Select a calibration factor set to use for simulation drop-down list and select the calibration factor set
you want to use.
10 FCC Reactor
519
3. Highlight the Calibration Factor set you want to use with the simulation.
4. Close the Calibration Factor Set dialog.
Your simulation will use the Calibration Factor set you selected.
Note: If the only Calibration Factor set shown is Default, click Library to edit, add,
delete, clone, import, and export Calibration Factor sets.
3. In the Factor Set group, enter the name of the new calibration factor set
in the Name field.
4. Click the Reactor page.
5. In the Reactor Factors group, specify the reactor variable information in
the appropriate cell.
6. Repeat steps 4 and 5 for the other pages.
Note:Depending on the configuration of the Refining operation, some options in a
page will not be available if the options are not applicable.
7. Click the Close icon when you are done specifying the calibration factor
set variables.
The Factor Set property view closes and you are returned to the Calibration Set Library property view.
520
10 FCC Reactor
3. On the Save Calibration Factor Set dialog, specify whether this Calibration Factor set should be used for the current simulation or not. The
default is yes.
4. In the Set Name field, enter the name for this Calibration Factor set.
5. Click Save to save this Calibration Factor set and exit the Save Calibration Factor Set dialog.
Tip:Click Cancel to exit the Save Calibration Factor Set dialog without saving
this Calibration Factor set.
4. In the Factor Set property view, select the page containing the variable
you want to modify.
Note:Depending on the configuration of the HYSYS Refining operation, some
options in a page will appear blank if the options are not applicable.
5. In the lower group, specify the modified variable values in the appropriate cell.
Tips:
o
You can modify the name of the calibration factor set by entering the new
name in the Name field located in the Factor Set group.
You can modify the description of the calibration factor set by entering
the information in the Description field located in the Factor Set group.
6. Click the Close icon when you are done modifying the calibration factor
set.
The Factor Set property view closes and you are returned to the Calibration Set Library property view.
10 FCC Reactor
521
3. On the Calibration Set Library dialog that appears, select the Calibration Factor set you want to delete.
4. Click Delete.
The Calibration Factor set you selected disappears from the Available Calibration Factor Sets list and is deleted from the Calibration Set Library.
522
10 FCC Reactor
4. In the Factor Set group, enter the new name in the Name field.
Tip:You can add a description for the calibration factor set by entering the information in the Description field.
5. In the left column, click the page containing the variable you want to
modify.
Note:Depending on the configuration of the HYSYS Refining operation, some
options in a page will not be available if the options are not applicable.
6. In the lower group, specify the modified variable values in the appropriate cell.
7. Click the Close icon when you are done modifying the calibration factor
set.
The Factor Set property view closes, and you are returned to the Calibration Set Library property view.
10 FCC Reactor
523
524
10 FCC Reactor
You can edit the following variables in the Factor Set property view:
l
Name of the calibration factor set: In the Factor Set group, enter the
name of the calibration factor set in the Name field.
Description of the calibration factor set: In the Factor Set group, enter
information about the calibration factor set in the Description field.
reactor variables
advanced options
fractionator variables
delumping variables
Notes:
l
The Date Created and Date Modified fields display the date and time the calibration factor set was created and last modified.
If the Hydrocracker does not contain a fractionator, than the Fractionator page
appears blank.
10 FCC Reactor
525
526
1.378
0.5890
1.618
9.156e-005
5.449
3.675
5.658
2.798
7.867
4.220
2.536
2.712
0.8972
1.249
0.2401
0.2484
0.2111
8.744e-003
2.060e-002
3.470e-002
0.1203
2.373e-002
0.1530
0.2550
1.785e-002
3.311e-002
9.299e-003
10 FCC Reactor
10 FCC Reactor
0.3000
0.3000
0.3333
0.3000
0.3000
1.669e-013
6.995e-014
5.264e-013
-1.128e-012
2.621e-014
0.7987
-10.72
0.7987
Stripper parameter
2.357
0.8301
15.30
-1.001
10.99
1.348e-002
8.235e-002
527
Factors
1.871
Note:In the Default Calibration Factor set, these Calibration Factors are read only. To
modify them, make a clone of the Default Calibration Factor set. You can then modify
any of the Calibration Factors in your cloned version.
528
Performance slope
1.000
0.1716
1.830
1.200
4.181e+007
0.5000
4.000e-002
10 FCC Reactor
10 FCC Reactor
Factors
0.1000
64.50
6.000e+004
0.6000
Riser/reactor term
0.0000
0.0000
0.0000
0.0000
0.0000
1.000e-004
0.2430
0.1500
3.114
529
530
Factors
0.000
0.5000
3.500
2.500
0.0000
2.940e-002
8.170e-002
7.370e-002
6.590e-002
0.1522
0.2005
6.590e-002
0.1522
0.2005
2.940e-002
8.170e-002
7.370e-002
6.590e-002
0.1522
0.2005
6.590e-002
0.1522
0.2005
4.150e-002
10 FCC Reactor
Factors
0.2828
0.4451
7.720e-002
7.720e-002
0.1622
0.2911
0.2683
7.850e-002
7.850e-002
7.850e-002
10
20
10 FCC Reactor
531
In the Default Calibration Factor set, these Calibration Factors are read-only.
To modify them, make a clone of the Default Calibration Factor set. You can
then modify any of the Calibration Factors in your cloned version.
l
532
3.650
0.0000
1.000
1.000
1.000
0.9624
1.000
1.000
1.000
1.000
LCO - Overall
.5648
0.000
LCO - Conversion
1.000
1.000
1.000
Bottoms - Overall
.8131
0.000
Bottoms - Conversion
1.000
1.000
1.000
2.010e-003
6.950e-003
LCO- Overall
4.329e-002
Bottoms- Overall
7.343e-002
10 FCC Reactor
10 FCC Reactor
2.354e-002
8.194e-002
LCO- Overall
0.1639
Bottoms- Overall
0.5936
0.7441
1.000
1.000
0.000
0.8666
1.000
1.000
0.000
LCO - Overall
1.077
LCO UOPK
1.000
LCO - Conversion
1.000
0.000
Bottoms - Overall
1.310
Bottoms UOPK
1.000
Bottoms - Conversion
1.000
0.000
-709.3
1.000
1.000
533
534
Factors
1.000
1.000
-91.32
1.000
1.000
1.000
1.000
LCO - Overall
1.000
LCO UOPK
1.000
LCO - Conversion
1.000
1.000
1.000
Bottoms - Overall
1.000
Bottoms UOPK
1.000
Bottoms - Conversion
1.000
1.000
1.000
51.64
1.000
1.000
1.000
0.000
68.32
1.000
1.000
10 FCC Reactor
10 FCC Reactor
Factors
1.000
0.000
LCO - Overall
1.000
LCO UOPK
1.000
LCO - Conversion
1.000
1.000
0.000
Bottoms - Overall
1.000
Bottoms UOPK
1.000
Bottoms - Conversion
1.000
1.000
0.000
16.75
1.000
1.000
1.000
0.000
36.39
1.000
1.000
1.000
0.000
LCO - Overall
1.000
LCO UOPK
1.000
535
536
Factors
LCO - Conversion
1.000
1.000
0.000
Bottoms - Overall
1.000
Bottoms UOPK
1.000
Bottoms - Conversion
1.000
1.000
0.000
LCO - Overall
65.14
1.000
64.34
1.000
1.000
1.000
11.42
1.000
1.000
1.000
76.60
1.000
1.000
10 FCC Reactor
Factors
1.000
14.87
1.000
1.000
1.000
10 FCC Reactor
537
538
Sulfur
Temperature
(C)
Temperature
(C)
45
0.0000
305
1.084
55
4.029e-002
315
1.684
65
0.4029
325
2.560
75
0.7659
335
3.474
85
0.9740
345
4.491
95
1.084
355
5.279
105
1.195
365
5.709
115
1.200
375
5.135
125
0.9311
385
4.176
135
0.6757
395
3.937
145
0.6441
405
4.418
155
0.6094
415
4.899
165
0.5696
425
5.228
175
0.5313
435
5.499
185
0.4950
445
5.770
195
0.4832
455
5.880
205
0.4566
470
5.901
215
0.4067
490
6.136
225
0.8058
510
6.253
235
1.328
530
6.354
245
1.016
550
6.449
255
0.8825
570
6.500
265
1.031
590
6.550
275
0.9080
625
6.590
285
0.8318
675
6.640
295
0.8432
775
6.657
1000
6.708
Basic Nitrogen
10 FCC Reactor
10 FCC Reactor
Temperature
(C)
Temperature
(C)
45
1.000
305
52.33
55
1.000
315
58.33
65
1.000
325
64.33
75
1.000
335
70.33
85
1.000
345
76.33
95
1.000
355
82.33
105
1.000
365
88.33
115
1.50
375
93.25
125
3.300
385
97.70
135
5.000
395
010.8
145
5.000
405
105.4
155
5.000
415
109.0
165
5.000
425
112.6
175
5.000
435
116.2
185
5.000
445
120.2
195
5.000
455
122.9
205
5.000
470
127.0
215
5.000
490
134.2
225
9.330
510
104.9
235
15.17
530
145.7
245
18.17
550
152.0
255
22.33
570
170.0
265
28.33
590
181.3
275
34.33
625
221.0
285
40.33
675
306.5
295
46.33
775
455.0
1000
752.0
CCR
539
540
Temperature
(C)
Temperature
(C)
45
1.000e-002
305
0.1000
55
1.000e-002
315
0.1000
65
1.000e-002
325
0.1000
75
1.000e-002
335
0.1000
85
1.000e-002
345
0.1000
95
1.000e-002
355
0.1233
105
1.000e-002
365
0.1833
115
1.500e-002
375
0.2325
125
3.300e-002
385
0.2775
135
5.000e-002
395
0.3180
145
5.000e-002
405
0.3540
155
5.000e-002
415
0.3900
165
5.000e-002
425
0.4260
175
5.000e-002
435
0.4620
185
5.000e-002
445
0.4980
195
5.000e-002
455
0.5340
205
5.000e-002
470
0.5700
215
5.000e-002
490
0.6420
225
7.167e-002
510
0.7093
235
0.1000
530
0.7573
245
0.1000
550
0.8040
255
0.1000
570
0.8400
265
0.1000
590
0.8760
275
0.1000
625
0.9120
285
0.1000
675
1.010
295
0.1000
775
1.460
1000
2.810
Gravity
10 FCC Reactor
10 FCC Reactor
Temperature
(C)
Temperature
(C)
45
0.7451
305
0.9174
55
0.7465
315
0.8545
65
0.7479
325
0.9936
75
0.7491
335
1.036
85
0.7582
345
1.081
95
0.7511
355
1.109
105
0.7519
365
1.107
115
0.7594
375
1.088
125
0.7853
385
1.064
135
0.8110
395
1.056
145
0.8132
405
1.064
155
0.8155
415
1.072
165
0.8177
425
1.084
175
0.8199
435
1.096
185
0.8222
445
1.110
195
0.8265
455
1.114
205
0.8309
470
1.120
215
0.8356
490
1.130
225
0.8391
510
1.140
235
0.8420
530
1.150
245
0.8434
550
1.159
255
0.8447
570
1.169
265
0.8460
590
1.174
275
0.8473
625
1.189
285
0.8501
675
1.210
295
0.8827
775
1.245
1000
1.310
Olefins
541
542
Temperature
(C)
Temperature
(C)
45
59.72
305
0.3410
55
57.53
315
0.3410
65
55.34
325
0.3410
75
53.15
335
0.3410
85
50.96
345
0.3410
95
48.77
355
0.3410
105
46.58
365
0.3410
115
42.84
375
0.3410
125
35.09
385
0.3410
135
27.57
395
0.3410
145
23.85
405
0.3410
155
20.74
415
0.3410
165
18.57
425
0.3410
175
16.73
435
0.3410
185
15.04
445
0.3410
195
13.70
455
0.3410
205
12.30
470
0.3410
215
10.81
490
0.3410
225
9.698
510
0.3410
235
8.636
530
0.3410
245
6.027
550
0.3410
255
3.478
570
0.3410
265
1.023
590
0.3410
275
0.3410
625
0.3410
285
0.3410
675
0.3410
295
0.3410
775
0.3410
1000
0.3410
Naphthenics
10 FCC Reactor
10 FCC Reactor
Temperature
(C)
Temperature
(C)
45
0.0000
305
11.62
55
2.778
315
11.30
65
5.932
325
10.99
75
9.087
335
10.69
85
12.24
345
10.38
95
15.40
355
10.09
105
18.55
365
9.790
115
20.17
375
9.500
125
17.81
385
9.220
135
17.57
395
8.930
145
17.18
405
8.660
155
16.81
415
8.380
165
16.43
425
8.110
175
16.06
435
7.850
185
15.70
445
7.580
195
15.33
455
7.330
205
14.98
470
6.950
215
14.62
490
6.450
225
14.27
510
5.980
235
13.93
530
5.520
245
13.58
550
5.070
255
13.25
570
4.650
265
12.91
590
4.230
275
12.58
625
3.550
285
12.26
675
2.660
295
11.93
775
1.180
1000
5.000e-002
Aromatics
543
544
Temperature
(C)
Temperature
(C)
45
0.0000
305
82.53
55
0.0000
315
83.15
65
0.0000
325
83.76
75
1.8201
335
84.36
85
4.384
345
84.95
95
6.948
355
85.53
105
9.511
365
86.09
115
14.56
375
86.64
125
26.08
385
87.18
135
37.33
395
87.71
145
44.12
405
88.23
155
50.21
415
88.73
165
55.19
425
89.22
175
58.06
435
89.70
185
60.12
445
90.17
195
62.49
455
90.63
205
64.42
470
91.29
215
65.67
490
92.13
225
77.10
510
92.92
235
77.82
530
93.67
245
78.53
550
94.36
255
79.23
570
95.01
265
79.91
590
95.61
275
80.58
625
96.45
285
81.24
675
97.34
295
81.89
775
98.82
1000
99.95
Cloud Point
10 FCC Reactor
10 FCC Reactor
Temperature
(C)
Temperature
(C)
45
0.0000
305
263.2
55
0.0000
315
268.6
65
0.0000
325
274.0
75
0.0000
335
279.4
85
0.0000
345
284.8
95
144.4
355
290.6
105
145.3
365
297.0
115
146.9
375
303.8
125
150.4
385
310.7
135
154.0
395
317.6
145
160.7
405
324.5
155
167.3
415
331.4
165
174.0
425
338.3
175
180.7
435
345.2
185
187.4
445
352.1
195
194.1
455
359.0
205
200.7
470
365.9
215
207.4
490
377.1
225
214.0
510
385.4
235
220.7
530
390.1
245
227.4
550
394.3
255
234.1
570
394.3
265
240.8
590
394.3
275
246.7
625
394.3
285
252.4
675
394.3
295
257.8
775
394.3
1000
394.3
RON
545
546
Temperature
(C)
Temperature
(C)
45
101.7
305
76.43
55
100.0
315
76.43
65
98.4
325
76.43
75
96.76
335
76.43
85
95.13
345
76.43
95
93.50
355
76.43
105
91.86
365
76.43
115
90.78
375
76.43
125
91.12
385
76.43
135
91.46
395
76.43
145
91.60
405
76.43
155
91.73
415
76.43
165
91.85
425
76.43
175
91.59
435
76.43
185
91.19
445
76.43
195
91.01
455
76.43
205
90.66
470
76.43
215
90.06
490
76.43
225
89.15
510
76.43
235
88.05
530
76.43
245
85.58
550
76.43
255
83.18
570
76.43
265
80.89
590
76.43
275
78.59
625
76.43
285
76.43
675
76.43
295
76.43
775
76.43
1000
76.43
MON
10 FCC Reactor
Temperature
(C)
Temperature
(C)
45
87.55
305
66.06
55
86.09
315
66.06
65
84.64
325
66.06
75
83.18
335
66.06
85
81.72
345
66.06
95
80.27
355
66.06
105
78.81
365
66.06
115
77.90
375
66.06
125
78.41
385
66.06
135
78.93
395
66.06
145
79.61
405
66.06
155
80.23
415
66.06
165
80.78
425
66.06
175
80.68
435
66.06
185
80.34
445
66.06
195
80.08
455
66.06
205
79.68
470
66.06
215
79.06
490
66.06
225
79.06
510
66.06
235
78.46
530
66.06
245
77.76
550
66.06
255
75.39
570
66.06
265
70.61
590
66.06
275
68.26
625
66.06
285
66.06
675
66.06
295
66.06
775
66.06
1000
66.06
10 FCC Reactor
547
The table below shows the key Calibration Factors for the Delumping page of
the Factor Set property view and the values for those factors in the Default Calibration Factor set.
In the Default Calibration Factor set, these Calibration Factors are read-only.
To modify them, make a clone of the Default Calibration Factor set. You can
then modify any of the Calibration Factors in your cloned version.
The Base Delumping Curve is shown below:
548
Temperature
(C)
Default Calibration
Factor set
Temperature
(C)
Default Calibration
Factor set
45
0.0000
305
1.845e-002
55
3.853e-003
315
1.768e-002
65
7.524e-003
325
1.707e-002
75
7.513e-003
335
1.653e-002
85
8.370e-003
345
1.603e-002
95
9.988e-003
355
1.540e-002
105
1.161e-002
365
1.457e-002
115
1.172e-002
375
1.344e-002
125
1.308e-002
385
1.217e-002
135
1.732e-002
395
1.083e-002
145
1.538e-002
405
9.435e-003
155
1.466e-002
415
8.042e-003
165
1.561e-002
425
6.905e-003
175
1.597e-002
435
5.893e-003
185
1.596e-002
445
5.940e-003
195
1.568e-002
455
1.232e-003
205
1.546e-002
470
7.811e-003
215
1.542e-002
490
6.226e-003
225
1.599e-002
510
4.938e-003
235
1.678e-002
530
3.914e-003
245
1.718e-002
550
2.979e-003
255
1.772e-002
570
2.333e-003
265
1.860e-002
590
4.871e-003
10 FCC Reactor
Temperature
(C)
Default Calibration
Factor set
Temperature
(C)
Default Calibration
Factor set
275
1.962e-002
625
3.540e-003
285
2.039e-002
675
8.777e-004
295
1.947e-002
775
1.434e-003
1000
0.0000
Catalyst Libraries
Catalyst libraries contain *.csv catalyst and catalyst blend files. The default location of the catalyst library for the FCC is \FCC\CatLibrary. You can work with
catalysts and you can also work with catalyst blends that you create yourself.
Adding Catalysts
You can add catalysts to the FCC. To add a catalyst:
1. Enter the FCC Environment.
2. On the FCC PFD, double-click on the FCC Reactor Section icon.
The Reactor Section Property View appears.
3. On the FCC Reactor Section property view, click the Catalyst tab.
10 FCC Reactor
549
Editing Catalysts
You can edit the specifications of catalysts. To edit a catalyst:
1. Enter the FCC Environment.
2. On the FCC PFD, double-click the FCC Reactor Section icon.
The Reactor Section Property View appears.
3. On the FCC Reactor Section property view, click the Catalyst tab.
4. Click the Library page.
5. On the Available Catalysts list, select the catalyst you want to edit.
6. Click Edit.
The FCC Catalyst View appears.
7. On the FCC Catalyst view, edit the properties of the catalyst you selected.
8. Close the FCC Catalyst view.
Deleting Catalysts
You can delete catalysts from the Library of Catalysts for the FCC. To delete a
catalyst:
1. Enter the FCC Environment.
2. On the FCC PFD, double-click the FCC Reactor Section icon.
The Reactor Section Property View appears.
3. On the FCC Reactor Section property view, click the Catalyst tab.
4. Click the Library page.
5. On the Available Catalysts list, select the catalyst you want to delete.
6. Click Delete.
The catalyst is deleted and its name disappears from the Available
Catalysts list of the Library page.
Cloning Catalysts
Cloning a catalyst creates a new catalyst with the exact same properties as the
original catalyst. To clone a catalyst:
550
10 FCC Reactor
Importing Catalysts
You can import catalysts. To import a catalyst:
1. Enter the FCC Environment.
2. On the FCC PFD, double-click on the FCC Reactor Section icon.
The Reactor Section Property View appears.
3. On the FCC Reactor Section property view, click the Catalyst tab.
4. Click the Library page.
5. Click Import.
The Available Catalysts view appears, showing a filtered list of Catalyst .csv files from which to choose. The folder in which the files reside
is the one specified in Simulation page of the Preferences view.
To access the Preferences property view, select File | Options.
6. Do one of the following:
o
10 FCC Reactor
551
Export Catalysts
To export a catalyst:
1. Enter the FCC Environment.
2. On the FCC PFD, double-click on the FCC Reactor Section icon.
The FCC Reactor Section property view appears.
3. On the FCC Reactor Section property view, click the Catalyst tab.
4. Click the Library page.
5. On the Library page, from the Available Catalysts list, select the Catalyst you want to export.
6. Click Export.
The File selection for exporting FCC Catalysts property view appears,
showing a filtered list of Catalyst *.csv files in the folder. The folder in
which the files reside is the one specified in Simulation page of the
Preferences view.
To access the Preferences property view, select File | Options.
7. In the File Name field, enter the name under which you want to save
the exported Catalyst.
8. Click Save.
The Catalyst is exported.
552
10 FCC Reactor
10 FCC Reactor
Object
Description
Name field
Description field
Manufacturer field
Methane cell
Ethylene cell
Ethane cell
Propylene cell
Propane cell
IC4 cell
N Butane cell
IC5 cell
NC5 cell
IC4= cell
1Butene cell
C2Butene cell
Butadene cell
Cyclopentane cell
3M1Butene cell
1Pentene cell
553
554
12Pentene cell
Cyclopentene cell
Isoprene cell
Benzene cell
Metals H2 cell
Metals H2 factor
Heat of Reaction
cell
HT Deact. cell
LN RON cell
LN MON cell
LN Nap cell
LN Olefins cell
LN Aromatics cell
SOx cell
SOX factor
HN RON cell
HN MON cell
HN Nap cell
HN Olefins cell
HN Aromatics cell
LN SPGR cell
HN SPGR cell
Zeolite (Wt. %)
cell
Zeolite content
Alumina (Wt. %)
cell
Alumina content
10 FCC Reactor
Sodium content
Nickel content
Vanadium (ppm)
cell
Vanadium content
Copper content
Iron content
Price cell
Delete button
Feed Libraries
Feed libraries contain *.csv feed and feed type files. The default location of the
feed library for the FCC is \FCC\FeedLibrary. You can work with feeds and
you can also work with feed types that you create yourself.
10 FCC Reactor
555
556
10 FCC Reactor
7. On the FCC Feed Type view, enter the name of the cloned Feed Type (or
accept the default name that HYSYS supplies).
If you want, on the FCC Feed Type view, edit any of the properties of the
cloned Feed Type.
8. Close the FCC Feed Type view.
The cloned Feed Type is added to the Library of Feed Type, and its name
appears on the Available Feed Type list of the Library page.
10 FCC Reactor
557
export.
6. Click Export.
The File selection for exporting FCC Feed Types view appears, showing a
filtered list of Feed Type .csv files in the folder. The folder in which the
files reside is the one specified in Simulation page of the Preferences
view.
To access the Preferences property view, select File | Options.
7. In the File Name field, enter the name under which you want to save
the exported Feed Type.
8. Click Save.
The Feed Type is exported.
From the FCC environment, open the 4 Reactor Section Property View,
select the Feed Data tab, select the Library page, and do one of the following:
o
Click Add to access the FCC Feed Type view of a new feed type.
From the Calibration environment, open the FCC Calibration view, select
the Feed Data tab, select the Library page, and do one of the following:
o
Click Add to access the FCC Feed Type view of a new feed type.
The following table lists and describes the options available in the FCC Feed
Type view:
558
Object
Description
Name field
Description field
10 FCC Reactor
Object
Description
Displays the date when the feed type was last modified.
Normalize button
Enables you to normalize the total kinetic lump weight percents to 100.
Delete button
Minimize f (x )
Subject to c(x ) = 0
x min x x max
where:
x
10 FCC Reactor
min
max
559
()
f x + ici
The Lagrange function,
, accounts for constraints through
weighting factors , often called Lagrange multipliers or shadow
i
prices.
4. Solve a quadratic programming sub-problem to determine a search direction, d . In the quadratic programming sub-problem:
k
5. Check for convergence or failure. If the optimization convergence criteria are satisfied, or if the maximum number of allowed iterations,
MAXITER, is reached, then end.
6. Convergence is achieved when:
o
560
Variable
Description
Default
MAXITER
20
MINITER
CREEPFLAG
No (0)
CREEPITER
10
10 FCC Reactor
Variable
Description
Default
CREEPSIZE
Creep mode step size. This is the fraction of the full step to be
taken when in creep mode.
0.1
RESCVG
1.0D-6
10 FCC Reactor
561
Overall
Model
The last seven lines of the output shows the execution times for the various
parts of the problem.
In this example, the convergence was achieved when the residual and objective
convergence functions were less than their respective tolerances at iteration 3.
From this output, there were no line searches. Thus, the step size for each iteration is one. When a line search is performed for an iteration, a message similar to the one below appears:
<Line Search ACTIVE> ==> Step taken 3.26D-01
If the solver has to line search continually and the step size gets very small
(less than 1.0D-2), most likely one of the following has occur:
l
The solution is trying to move very far from the starting point.
562
<case name>.ATSLV
<case name>.ATACT
10 FCC Reactor
The ATACT file is similar to the ATSLV file, but lists all the problem variables
and independent variables, whereas the ATSLV file does not. The ATSLV file is
typically more useful.
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
10 FCC Reactor
563
564
10 FCC Reactor
Constrained Variables
The table below shows the variables that lie on their bounds. This is only meaningful in a degree-of-freedom (optimization) mode.
The shadow price: The shadow price is also known as the Lagrange multiplier. This is the derivative of the objective function with respect to the
value of the constraint. It represents the cost for the constraint.
The shadow price is based on the value of the objective function that is seen by
DMO. That means the shadow price is in SI units (such as $/sec) and is affected
by any scaling. This is true even if you declare the units to be something other
than SI (such as $/hr).
Consider this example. We have a tower with a composition constraint,
expressed as a mole fraction of a component. The following table shows the results of two optimization runs at two different values of the composition constraint:
Constraint Value
Objective Function
Shadow Price
0.0002
2.853
432.924
0.0003
2.893
258.664
The large change in the shadow price indicates that the effect of the composition on the objective function is very nonlinear. We can manually estimate
the average shadow price in this region by a finite difference method:
10 FCC Reactor
565
Objective Function
Shadow Price
0.0002
285.4
43290.7
0.0003
289.3
25860.2
Indicates
Normal
Warning
Error
A failure
Solved
566
10 FCC Reactor
Nonlinearity Ratio
The Nonlinearity Ratio information shows the nonlinearity ratio of:
l
worst block
objective function
worst equations
RXRG = 0.93489
10 FCC Reactor
567
Troubleshooting
DMO Solver Problems
The Troubleshooting information in the Trace Window describes some
troubleshooting tips to improve the performance of the solver and to help diagnose common problems.
568
10 FCC Reactor
10 FCC Reactor
569
570
Ea/R
Pre-exponential
-11.052
10000
1.540
20000
14.132
30000
26.724
40000
39.316
50000
51.908
60000
64.500
10 FCC Reactor
70000
77.092
80000
89.684
90000
102.276
100000
114.868
5. Run the calibration case to pivot other cracking kinetics around the new
assumed values for overcracking.
6. Go to the FCC simulation environment and test the model response in the
simulation runs by using the case study feature of plotting naphtha yield
as a function of riser or reactor outlet temperature.
7. You may need to iterate on this a few times to obtain the desired overcracking peak.
Note: Overcracking factors can only be changed in a calibration run to set the
stage for testing in the simulation environment. Do not change these factors in a
simulation run.
10 FCC Reactor
571
572
10 FCC Reactor
11 Hydroprocessor Bed
Hydroprocessor Bed in EO
The Hydroprocessor Bed can also be placed in an EO subflowsheet provided that
you have specified a component slate suitable for the Hydroprocessor Bed in
the subflowsheet.
To do this, import hcr.aprbkp in the Properties environment (the Import option
for the Fluid Pkgs allows the user to specify an aprbkp file). The basis associated with this fluid package (specifically the RTOSRK fluid package) should be
11 Hydroprocessor Bed
573
Saturation Activity: This is a multiplier on the pre-exponential terms for all of the saturation reaction pathways. This
can be adjusted up or down to match the product aromatics.
Ring-Opening Activity: This is a multiplier on the pre-exponential terms for all ring-opening pathways. While there is not a
one-to-one correspondence with any product property or yield,
this can be used to help achieve yield targets or hydrogen consumption targets.
2. Specify the olefin content of the feed. To do so, you can either:
o
574
11 Hydroprocessor Bed
Specify the Bromine Number. HYSYScalculates the olefin content from the bromine number.
Note: Depending on the composition of the feed, it is possible for the olefin content to become negative if you specify the Bromine Number. We recommend
that unless you have high quality feed data and bromine measurements, you specify the olefin content directly.
11 Hydroprocessor Bed
Medium Saturation Activity: Multiplier on the pre-exponential term that affects saturation reactions in the distillate
range.
Light Desulfurization Activity: Multiplier on the pre-exponential term that affects HDS reactions in the naphtha range.
Medium Desulfurization Activity: Multiplier on the pre-exponential term that affects HDS reactions in the distillate range.
Heavy Desulfurization Activity: Multiplier on the pre-exponential term that affects HDS reactions in the gasoil and resid
range.
Light Denitrogenation Activity: Multiplier on the pre-exponential term that affects HDN reactions in the naphtha and distillate range.
Heavy Denitrogenation Activity: Multiplier on the pre-exponential term that affects HDN reactions in the gasoil and resid
range.
Light Ring-opening Activity: Multiplier on the pre-exponential term that affects ring-opening reactions in the naphtha
range.
Medium Ring-opening Activity: Multiplier on the pre-exponential term that affects ring-opening reactions in the distillate
575
range.
o
Heavy Ring-opening Activity: Multiplier on the pre-exponential term that affects ring-opening reactions in the gasoil
and resid range.
HDSScaling
HDNScaling
HBEDProperty View
HBEDSimulation
Specifying HBED Bed Connections
Use the Connections page on the Simulation tab of the Hydroprocessor Bed
property view to specify streams associated with the Hydroprocessor Bed.
To specify HBED connections:
1. From the PFD, double-click the HBED icon. The Hydroprocessor Bed property view appears.
2. Click the Simulation tab.
3. Click the Connections page.
4. Specify the following values:
576
11 Hydroprocessor Bed
Object
Input Required
Name
Contains the name of the Unit Op. You can edit the name at any
time by typing in a new name in the Name field.
Fluid
Package
Feed
Connects a single feed. You can either type in the name of the
stream or if you have pre-defined your stream select it from the
drop-down list.
Product
Connects the product stream. You can either type in the name of the
stream or if you have pre-defined your stream select it from the
drop-down list.
Input Required
Reactor Diameter
Reactor Length
Catalyst Density
Void Fraction
11 Hydroprocessor Bed
577
Typically, you will tune the Hydroprocessor Bed using only the factors on the
Simulation tab | Basic Tuning page.
Note that it is possible for the olefin content to go negative if the bromine number is entered depending on the composition of the feed. It is recommended
that unless you have high quality feed data and bromine measurements that
you input the olefin content directly.
If all of the reactions seem to be too slow or too fast, the global activity can be
adjusted up or down to match. If only the cracking activity is too low or too
high, the cracking activity can be adjusted up or down to match.
To performing basic tuning for the HBED:
1. From the PFD, double-click the Hydroprocessor Bed icon. The Hydroprocessor Bed property view appears.
2. Click the Simulation tab.
3. Click on the Basic Tuning page.
4. Specify values for the following:
o
Saturation Activity: This is a multiplier on the pre-exponential terms for all of the saturation reaction pathways. This
can be adjusted up or down to match the product aromatics.
Ring-Opening Activity: This is a multiplier on the pre-exponential terms for all ring-opening pathways. While there is not a
one-to-one correspondence with any product property or yield,
this can be used to help achieve yield targets or hydrogen consumption targets.
5. Specify the olefin content of the feed. To do so, you can either:
o
578
11 Hydroprocessor Bed
Specify the Bromine Number. HYSYScalculates the olefin content from the bromine number.
Note: Depending on the composition of the feed, it is possible for the olefin content to become negative if you specify the Bromine Number. We recommend
that unless you have high quality feed data and bromine measurements, you specify the olefin content directly.
11 Hydroprocessor Bed
Medium Saturation Activity: Multiplier on the pre-exponential term that affects saturation reactions in the distillate
range.
Light Desulfurization Activity: Multiplier on the pre-exponential term that affects HDS reactions in the naphtha range.
Medium Desulfurization Activity: Multiplier on the pre-exponential term that affects HDS reactions in the distillate range.
Heavy Desulfurization Activity: Multiplier on the pre-exponential term that affects HDS reactions in the gasoil and resid
range.
Light Denitrogenation Activity: Multiplier on the pre-exponential term that affects HDN reactions in the naphtha and distillate range.
579
Light Ring-opening Activity: Multiplier on the pre-exponential term that affects ring-opening reactions in the naphtha
range.
Medium Ring-opening Activity: Multiplier on the pre-exponential term that affects ring-opening reactions in the distillate
range.
Heavy Ring-opening Activity: Multiplier on the pre-exponential term that affects ring-opening reactions in the gasoil
and resid range.
HDSScaling
HDNScaling
580
11 Hydroprocessor Bed
To access:
1. From the PFD, double-click the HBED icon. The Hydroprocessor Bed property view appears.
2. Click the Simulation tab.
3. Click the Profiles page.
HBED Deactivation
The Deactivation page gives an estimate of how quickly your bed is deactivating.
The deactivation must be tuned for each bed. You must input the WABT at the
start of the cycle as well as the WABT at the end of the cycle along with remaining days on stream. You can also modify the initial and long-term deactivation
constants and the activation energy for deactivation. The deactivation rate is
based on the deactivation constants specified as well as the feed quality
(amount of PNAs) and hydrogen partial pressure.
To access:
1. From the PFD, double-click the HBED icon. The Hydroprocessor Bed property view appears.
2. Click the Simulation tab.
3. Click the Deactivation page.
Solver Tab
Simulation Engine
The Simulation Engine page of the Solver tab allows you to enter OOMF
script language commands for special tasks. For instance, you can print or
retrieve a particular variable. For more advanced usage, you can use the simulation engine for troubleshooting, or changing advanced options such as solver
tolerances.
Some examples of OOMF script command:
l
The following table describes the objects available on the Simulation Engine
page.
11 Hydroprocessor Bed
581
Button
Description
Clear Messages
Clears all the existing messages in the OOMF script commands window.
Update
Messages
Checks for new simulation messages and appends them to the messages
that are already in the OOMF script commands window.
Get Pre.
Command
Run Command
Solve
HYSYS
In the History Size Lines field, enter the line number showing in the OOMF
Simulation Engine Messages and Script Commands field.
In the Solve Failure Recovery Options field, you can select one of the following action in case of failure:
l
Do Nothing
Solver Settings
On the Solver Settings page of the Solver tab of the HBED, you can change
settings such as number of iterations and creep steps.
582
Settings
Description
Convergence
Tolerance
Maximum Iterations
Minimum Iterations
Contains three fields that enable you to configure the creep function of the Solver:
l
Creep Steps On check box. Select On (enable) or Off (disable) option for the creep feature.
11 Hydroprocessor Bed
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
Presolve Commands
Using the Presolve Commands page on the Solver tab, you can specify commands to run before the EO solution.
Click Clear All to return to the default settings.
Postsolve Commands
Using the Postsolve Commands page on the Solver tab, you can specify commands to run after the EO solution.
Click Clear All to return to the default settings.
11 Hydroprocessor Bed
583
584
11 Hydroprocessor Bed
The Isomerization Unit Operation is a detailed kinetic model of the isomerization unit. It models isomerization, hydrocracking, ring-opening, saturation, and heavy reactions. The model uses the same component slate as
Refining Reformer, although only a subset of approximately 25 components are
used for the reaction scheme. Since a typical isomerization feed would have no
olefins or C8 and above material, any olefins are mapped into their corresponding paraffins, and all C8 components and above are mapped into the C8
6-ring naphthenic component.
The Isomerization reactor is manually tuned. The isomerization unit models
one reactor. Most typical setups will have two isomerization units in the flowsheet representing the lead and lag reactors.
The reactor is modeled using the Aspen EORXR model. The rate expression for
each reaction class has been coded to match literature data. The isomerization
and hydrogenation reactions are considered to be reversible, and the other reaction classes are all considered to be irreversible. Each reaction class is first
order with respect to the primary reactant. Each reaction class also has a
denominator term following typical LHHW.
Before placing an Isomerization unit in a flowsheet, you should first define an
appropriate component slate. From the Properties environment, you can import
the file CatRefIsom.cml. This file is located in your HYSYS install directory
under the paks directory. The fluid package should be defined as SRK or Peng
Robinson. Alternatively, you can use Aspen Properties and use the file catref.aprbkp to define the components and the fluid package. This file is located in
your HYSYS install directory under the RefSYS\refreactor directory. If the
correct component slate has not been defined for the part of the flowsheet in
which the Isom unit op is placed, the model will still initialize; however, the
model will not be able to execute until a basis with an appropriate component
slate is selected.
Once an appropriate component slate and fluid package have been created for
the Isom model, you can go into the simulation environment and place an Isom
585
unit operation in the flowsheet. You can add this to the flowsheet either by
using the model palette (F4), or by adding a unit operation (F12) and selecting
the Isom unit op from the list of unit operations. It will take a short while after
the block has been placed to initialize the block.
For information regarding the Kinetic Lumps, refer to IsomerizationUnit Kinetic
Lumps.
Simulation
Major Simulation Inputs
l
Global Activity
Isomerization Activity
Hydrocracking Activity
Hydrogenation Activity
Ring-opening Activity
Heavy Activity
Hydrogen consumption
586
Description
H2
Hydrogen
P1
Methane
P2
Ethane
P3
Propane
IP4
isoButane
NP4
Butane
IP5
isoPentane
NP5
Pentane
5N5
cyclopentane
22DMC4
2,2-dimethylbutane
23DMC4
2,3-dimethylbutane
2MC5
2-methylpentane
3MC5
3-methylpentane
NP6
hexane
5N6
5_Napthene6
A6
C6_aromatics
6N6
6_Napthene6
22DMC5
2,2-dimethylpentane
23DMC5
2,3-dimethylpentane
24DMC5
2,4-dimethylpentane
2MC6
2-methylhexane
3MC6
3-methylhexane
3EC5
3-ethylpentane
NP7
heptane
DMCP
dimethylcyclopentane
ECP
ethylcyclopentane
A7
C7_aromatics
6N7
6_Napthene7
6N8
6_Napthene8
587
3. From the list of available unit operations select the Isom Unit Op model.
4. Click the Add button. The Isom Unit Op view appears.
OR
1. From the Flowsheet menu, select Refining Operations. The Refinery
object palette appears.
2. Double-click the ISOM icon. The Isom Unit Op property view appears.
Isom in EO
The Isom Unit Op can also be placed in an EO subflowsheet provided that you
have specified a component slate suitable for the Isom Unit in the subflowsheet.
To do this, you should import catref.aprbkp in the Properties environment
(the Import option for the Fluid Pkgs lets you specify an aprbkp file). The
basis associated with this fluid package (specifically the RTOSRK fluid package)
should be applied to the EO subflowsheet to which you want to add the Isom
Unit.
Once this is done, you can add the Isom Unit Op by pressing F12 and selecting
Isom Unit Op from the list of available unit ops.
The forms and connections work the same as the SM version.
588
Isomerization Activity: This is a multiplier on the pre-exponential terms for all isomerization reactions. This can be adjusted up or down to match the desired isomerization target such
as the PIN or the C5+ RON.
Hydrocracking Activity: This is a multiplier on the pre-exponential terms for all hydrocracking reactions. This can be adjusted up or down to match the light ends in the product.
Hydrogenation Activity: This is a multiplier on the pre-exponential term for benzene saturation. This can be adjusted up or
down to match the benzene content of the product.
Ring-opening Activity: This is a multiplier on the pre-exponential terms for all ring-opening reactions. This can be adjusted up or down to match the naphthene content of the product.
n-Hexane to 2-Mpentane
2-Mpentane to 23-MButane
2-MPentane to 3-MPentane
23-MButane to 22-MButane
n-Pentane to i-Pentane
CH to MCP
Benzene Saturation
n-Hexance Cracking
2-MPentane Cracking
3-MPentane Cracking
22-MButane Cracking
23-MButane Cracking
i-Pentane Cracking
MCP Ring-opening
CP Ring-opening
MCH Ring-opening
n-Heptane Cracking
n-Butane to i-Butane
o n-Butane Cracking
Adjusting the reference rate changes the reaction rate, and adjusting the
activation energy changes the temperature response for that reaction.
589
Tip:Click the Ignored check box to tell HYSYS Refining ignore the unit operation when
solving the simulation.
Simulation Tab
Specifying Isom Connections
Use the Connections page on the Simulation tab of the Isom property view to
specify streams associated with the Isom.
To access:
1. From the PFD, double-click the Isom icon. The Isom property view
appears.
2. Select the Simulation tab | Connections page.
3. Specify values for the following:
Object
Input Required
Name
Contains the name of the Isom Unit Op. You can edit the name of
the Isom at any time by typing in a new name in the Name field.
Fluid
Package
Feed
Connects a single feed to the Isom. You can either type in the name
of the stream or if you have pre-defined your stream select it from
the drop-down list.
Product
Connects the product stream to the Isom. You can either type in the
name of the stream or if you have pre-defined your stream select it
from the drop-down list.
590
Object
Input Required
Reactor Diameter
Object
Input Required
Reactor
Length
Catalyst
Density
Void Fraction
Specify
Reactor Type
Isomerization Activity: This is a multiplier on the pre-exponential terms for all isomerization reactions. This can be adjusted up or down to match the desired isomerization target such
as the PIN or the C5+ RON.
Hydrocracking Activity: This is a multiplier on the pre-exponential terms for all hydrocracking reactions. This can be adjusted up or down to match the light ends in the product.
Hydrogenation Activity: This is a multiplier on the pre-exponential term for benzene saturation. This can be adjusted up or
down to match the benzene content of the product.
Ring-opening Activity: This is a multiplier on the pre-exponential terms for all ring-opening reactions. This can be
591
n-Hexane to 2-Mpentane
2-Mpentane to 23-MButane
2-MPentane to 3-MPentane
23-MButane to 22-MButane
n-Pentane to i-Pentane
CH to MCP
Benzene Saturation
n-Hexance Cracking
2-MPentane Cracking
3-MPentane Cracking
22-MButane Cracking
23-MButane Cracking
i-Pentane Cracking
MCP Ring-opening
CP Ring-opening
MCH Ring-opening
n-Heptane Cracking
n-Butane to i-Butane
n-Butane Cracking
Adjusting the reference rate changes the reaction rate, and adjusting the
activation energy changes the temperature response for that reaction.
o
592
Solver Tab
Simulation Engine
The Simulation Engine page of the Solver tab allows you to enter OOMF
script language commands for special tasks. For instance, you can print or
retrieve a particular variable. For more advanced usage, you can use the simulation engine for troubleshooting, or changing advanced options such as solver
tolerances.
Some examples of OOMF script command:
l
The following table describes the objects available on the Simulation Engine
page.
Button
Description
Clear Messages
Clears all the existing messages in the OOMF script commands window.
Update
Messages
Checks for new simulation messages and appends them to the messages
that are already in the OOMF script commands window.
Get Pre.
Command
Run Command
Solve
HYSYS
593
In the History Size Lines field, enter the line number showing in the OOMF
Simulation Engine Messages and Script Commands field.
In the Solve Failure Recovery Options field, you can select one of the following action in case of failure:
l
Do Nothing
Object
Description
Convergence
Tolerance
Contains the Residual field that lets you specify the maximum residual value allowed for the convergence calculation.
Iteration Lim- Contains two fields that enable you to control the iteration range for
its
the Solver performance:
Creep Step
Parameters
Maximum Iterations field lets you specify the maximum number of iterations.
Minimum Iterations field lets you specify the minimum number of iterations.
Contains three fields that enable you to configure the creep function
of the Solver:
l
Step Size field. Lets you specify the size of each creep step.
To access:
1. From the PFD, double-click the Isom icon. The Isom property view
appears.
2. Click the Solver tab.
3. Click the Solver Settings page.
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
594
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
Presolve Commands
Using the Presolve Commands page on the Solver tab, you can specify commands to run before the EO solution.
Click Clear All to return to the default settings.
Postsolve Commands
Using the Postsolve Commands page on the Solver tab, you can specify commands to run after the EO solution.
Click Clear All to return to the default settings.
595
596
13 Delayed Coker
The Delayed Coker model lets you build, calibrate, and simulate delayed coker
units in a HYSYS PFD. This model represents only the reactor sections of the
delayed coker (the furnace and drum).
For information regarding the Kinetic Lumps, refer to Delayed Coker Kinetic
Lumps.
Simulation
Major Simulation Inputs
l
Crack to Naphtha
Cracking Activity
Coking Activity
Crack to H2S
Drum T
Product yields:
13 Delayed Coker
597
Specific gravity, sulfur, nitrogen, paraffins, olefins, naphthenes, and aromatics. Viscosity, MW, and Conradson Carbon
are also predicted for the product stream.
Calibration
Calibration requires all of the same inputs as simulation, except for the kinetic,
property, and miscellaneous coefficients highlighted above.These are calculated by the calibration case.In order to calculate these coefficients and
factors, the calibration requires some product data.
598
Lump
Description
H2S
Hydrogen Sulfide
Lights
Gasoline
GS
Gasoline S
LP
Light Paraffins
LPS
Light Paraffin S
LN
Light Naphthenes
LAA1
LAA2
13 Delayed Coker
Lump
Description
LASA1
LDA1
HP
Heavy Paraffins
HPS
Heavy Paraffin S
HN
Heavy Naphthenes
HAA1
HAA2
HAA3
HASA1
HASA2
HASA3
HDA2
HDA3
RP
Resid Paraffins
RPS
Resid Paraffin S
RN
Resid Naphthene
RAA1
RAA2
RAA3
RAA4
RASA1
RASA2
RASA3
RASA4
RDA3
RDA4
COKE
Coke
H2O
Water
599
For each product square cut, the relationship of these factors are as follows:
Sulfur
(
)
+ KDPin(DPin DPin _base) + KCFR (CFR CFR base) + KSG(SGfeed SGfeed _base)
+ KSfeed (S feed S feed _ base) + KCCR(CCR CCR base)
S prod = S feed * KSfeed * Base + KDTin DTin DTin _base
Exposed Variables
= Feed sulfur factor
K
Sfeed
Base = Base factor
= Drum inlet temperature factor
K
DTin
DPin
CFR
SG
CCR
Other Variables
S
prod
feed
feed_base
DT
DT
DP
DP
CFR
CFR
SG
in
in_base
in
in_base
base
feed
Specific Gravity
SGprod = Base + KSG + KDTin DTin DTin_ base + KDPin DPin DPin _base
+ KCFR CFR CFR base + KSG SGfeed SGfeed _base + KCCR CCR CCR base
600
13 Delayed Coker
Exposed Variables
K
= Specific gravity factor
SG
K
= Drum inlet temperature factor
DTin
= Drum inlet pressure factor
K
DPin
CFR
CCR
Other Variables
SG
prod
Base
DT
DT
DP
DP
CFR
CFR
SG
SG
CCR
CCR
in
in_base
in
in_base
base
feed
feed_base
base
Nitrogen
)
(
)
+ KCFR (CFR CFR base) + KSG(SGfeed SGfeed _ base) + KSfeed (S feed S feed _ base)
+ KNfeed(N feed N feed _base)
N prod = N feed * KNfeed * Base + KDTin DTin DTin_ base + KDPin DPin DPin _base
Exposed Variables
= Feed nitrogen factor
K
Nfeed
Base = Base factor
= Drum inlet temperature factor
K
DTin
K
K
DPin
CFR
SG
Sfeed
13 Delayed Coker
601
Other Variables
N
prod
N
feed
feed_base
DT
DT
DP
DP
CFR
CFR
SG
SG
= Feed sulfur
in
in_base
in
in_base
base
feed
feed_base
feed
feed_base
Aromatics
(
)
(
)
+ KCFR(CFR CFR base) + KSG(SGfeed SGfeed _base) + KCCR(CCR CCR base)
Arom prod = Base +KDTin DTin DTin _base + KDPin DPin DPin_ base
Exposed Variables
= Drum inlet temperature factor
K
DTin
K
= Drum inlet pressure factor
DPin
= Combined feed ratio factor
K
CFR
K
= Specific gravity factor
SG
K
= Conradson carbon content factor
CCR
Other Variables
Arom
prod
Base
DT
DT
DP
DP
CFR
CFR
SG
SG
in
in_base
in
in_base
base
feed
feed_base
602
13 Delayed Coker
CCR
CCR
base
Naphthenes
(
) + K (SG
Naph prod = Base +KDTin DTin DTin _base + KDPin DPin DPin _base
SG
feed
Exposed Variables
= Drum inlet temperature factor
K
DTin
K
= Drum inlet pressure factor
DPin
= Combined feed ratio factor
K
CFR
K
= Specific gravity factor
SG
K
= Conradson carbon content factor
CCR
Other Variables
Naph
prod
Base
DT
DT
DP
DP
CFR
CFR
SG
SG
CCR
CCR
in
in_base
in
in_base
base
feed
feed_base
base
Olefins
Olef prod = Base +KDTin DTin DTin _base + KDPin DPin DPin _base
+ KCFR CFR CFR base + KSG SGfeed SGfeed _ base + KCCR CCR CCR base
Exposed Variables
= Drum inlet temperature factor
K
DTin
K
= Drum inlet pressure factor
DPin
13 Delayed Coker
603
Other Variables
Olef
prod
Base
DT
DT
DP
DP
CFR
CFR
SG
SG
CCR
CCR
in
in_base
in
in_base
base
feed
feed_base
base
604
13 Delayed Coker
Specifying Input
To specify input:
1. On the Input page of the Simulation tab, in the Furnace Specifications
section, specify values for the following:
o
Combined Feed Ratio: Type the ratio of the coker feed entering from the coker fractionator divided by the fresh feed entering the coker fractionator.
Drum Outlet T: Calculated from the Theoretical Drum Outlet Temperature and the heat loss calculated from calibration.
Theoretical Drum Outlet T: The Theoretical Drum Temperature is calculated using the other input variables specified
on this page.
Notes:
l
If you have not yet run a calibration for your model, the Drum Outlet T and Theoretical Drum Outlet T fields will both contain the same value.
The steam stream is created internally and does not need to be created on the flowsheet.
Once you have typed all the necessary Input information, the model solves
using the default set of tuning factors.
13 Delayed Coker
605
606
Feed properties input from stream: Includes the properties that the
delayed coker reads from the stream that it needs to calculate the kinetic lumps that it uses. The properties are Specific Gravity, Sulfur Content, Conradson Carbon Content, Nitrogen Content and D2887 9 point
distillation.
Feed properties calculated from stream: HYSYS takes the properties listed in the Feed properties input from stream section and
calculates properties more directly related to the kinetic lumps: Watson
K, and from the Watson K estimates Paraffins, Naphthenes, and Aromatics.
Feed lump composition (wt%): HYSYS uses the Paraffins, Naphthenes and Aromatics, along with the distillation and the Conradson
Carbon Content, to calculate the kinetic lumps going into the coker. In
theFeed lump composition section, you can view calculated values
for the following fields:
HP
HPS
HN
HAA1
HAA2
HAA3
HASA1
HASA2
HASA3
HDA2
HDA3
RP
Resid Paraffin
RPS
Resid Sulfides
RN
Resid Naphthenes
RAA1
RAA2
RAA3
RAA4
RASA1
RASA2
RASA3
RASA4
RDA3
RDA4
13 Delayed Coker
Volume Flowrate
Mass Flow
Volume Yields
Mass Yields
The mass and volume yields are the percentage of total feed to the coker. The
volume flow and volume yield of Fuel Gas is on an FOE basis.
Specific Gravity
Sulfur
Nitrogen
Note: Coke Sulfur = (Feed Mass * Feed Sulfur - Product Mass * Product Sulfur)/Coke Mass
Crack to Naphtha
Cracking Activity
Coking Activity
Crack to H2S
In the Property Factors section, you can edit the following factors if desired:
l
SG Parameters
Sulfur Parameters
13 Delayed Coker
607
Nitrogen Parameters
Olefins Parameters
Naphthenes Parameters
Aromatics Parameters
Note: The Sulfur and Nitrogen parameters are multipliers and should always have positive values. If the Sulfur or Nitrogen parameter has a negative value, check your data
entry. The SG, Aromatics, Naphthenes, and Olefins are additive parameters and can
have positive or negative values. Refer to Delayed Coker Equations for further details.
Notes Page
Using the Notes page on the Simulation tab, you can type notations for the
Delayed Coker.
608
13 Delayed Coker
and
l
Composition
Note: H2Sis calculated by the difference when a sulfur balance is performed: H S = Feed
2
Sulfur - Liquid Product S - Coke S.
13 Delayed Coker
609
Calibration Results
On the Calibration Results page of the Calibrate tab, you can view calibration factors and cut measurements. You can also transfer calibration data to
simulation using the Transfer to Simulation button.
In the Kinetic Factors section, results for the following appear:
l
Crack to Naphtha
Cracking Activity
Coking Activity
Crack to H2S
610
SG Parameters
Sulfur Parameters
Nitrogen Parameters
Olefins Parameters
Naphthenes Parameters
Aromatics Parameters
13 Delayed Coker
13 Delayed Coker
Sulfur to hydrocarbon cracking ratio: How reactive nonring sulfur is in comparison to hydrocarbons. According to the
literature, sulfide components crack slightly faster than pure
hydrocarbons. The default value is 1.1, meaning that non-ring
sulfur is 10% more reactive than hydrocarbons.
Light Activity: The ability of 650- material to crack. The activity for any light (LGO and lighter) material. The default value is
0, since it is assumed that light material will be vaporized and
quickly exit the coker drum.
Aromatics Coking Activity: This is the activity for 1-ring aromatic material to coke. This is much less active to coke that
multi-ring aromatics, but higher than saturates. Increasing this
value relative to the multi-ring aromatics coking activity makes
the model less sensitive to Conradson carbon content in order
to meet the coke target.
611
Sulfur
Specific Gravity
Nitrogen
Aromatics
Naphthenes
Olefins
Temperature
Sulfur Content
Nitrogen Content
ConCarbon Content
Specific Gravity
Olefin Curve
Naphthenic Curve
Aromatic Curve
CloudPoint
RON
MON
Note: Click the Restore Defaults button to return to the default values.
612
Vapor
Temperature
13 Delayed Coker
Pressure
Molar Flow
Mass Flow
Molar Enthalpy
Molar Entropy
Heat Flow
Properties
On the Properties page of the Worksheet tab, you can edit the properties of
the inlet and outlet streams.
Composition
On the Composition page of the Worksheet tab, you can edit the composition
of the inlet and outlet streams.
Do Nothing
Reset Variables
Restore Variables
Solver Settings
On the Solver Settings page of the Solver tab for the Delayed Coker, you can
change EO settings, such as number of iterations and creep steps.
To edit solver settings:
1. In the Convergence Tolerance field, type an appropriate value.
2. Adjust the Maximum Iterations and Minimum Iterations as desired.
3. Select the Creep Steps On check box if you want to use creep iterations.
Note: Selecting this option makes the optimizer take smaller steps for a
13 Delayed Coker
613
Presolve Commands
Using the Presolve Commands page on the Solver page, you can specify
commands to run before the EO solution.
Click Clear All to return to the default settings.
Postsolve Commands
Using the Postsolve Commands page on the Solver tab, you can specify commands to run after the EO solution.
Click Clear All to return to the default settings.
614
13 Delayed Coker
13 Delayed Coker
615
616
13 Delayed Coker
14 Visbreaker
The Visbreaker model lets you build, calibrate, and simulate visbreaker units in
a HYSYS PFD. This model represents only the reactor sections of the visbreaker
(the furnace and optional soaking drum).
For information regarding the Kinetic Lumps, refer to Visbreaker Kinetic Lumps.
Simulation
Major Simulation Inputs
l
Crack to Naphtha
Cracking Activity
Coking Activity
14 Visbreaker
Product yields:
o
Heavy components: C5-350F naphtha, 350-650F distillate, 650950F gasoil, 950+ tar
617
Calibration
Calibration requires all of the same inputs as simulation, except for the kinetic,
property, and miscellaneous coefficients highlighted above.These are calculated by the calibration case.In order to calculate these coefficients and
factors, the calibration requires some product data.
618
Lump
Description
H2S
Hydrogen Sulfide
Lights
Gasoline
GS
Gasoline S
LP
Light Paraffins
LPS
Light Paraffin S
LN
Light Naphthenes
LAA1
LAA2
LASA1
LDA1
HP
Heavy Paraffins
HPS
Heavy Paraffin S
14 Visbreaker
HN
Heavy Naphthenes
HAA1
HAA2
HAA3
HASA1
HASA2
HASA3
HDA2
HDA3
RP
Resid Paraffins
RPS
Resid Paraffin S
RN
Resid Naphthene
RAA1
RAA2
RAA3
RAA4
RASA1
RASA2
RASA3
RASA4
RDA3
RDA4
COKE
Coke
H2O
Water
Visbreaker Equations
For each product square cut, the relationship of these factors are as follows:
Sulfur
(
+ K Conv 350(Conv 350 Conv 350_base )
14 Visbreaker
619
Exposed Variables
K
Sfeed
Conv350
Other Variables
S
S
feed_base
Base
prod
feed
Conv
Conv
350
350_base
Specific Gravity
SGfeed
Sfeed
Conv350
Other Variables
SG
prod
Base
SG
SG
feed
feed_base
feed
feed_base
Conv
= 350 F conversion
Conv
350
350_base
Nitrogen
Nfeed
620
14 Visbreaker
Other Variables
N
14 Visbreaker
621
Specifying Input
To specify input:
1. On the Input page of the Simulation tab, in the Furnace Outlet Temperature field, type the operating outlet temperature of the furnace.
2. In the Furnace Pressure field, type the operating outlet pressure of
the furnace.
3. In the Feed Steam Mass field, type the steam mass flowrate.
4. In the Feed Steam Temperature field, type the steam temperature.
5. In the Feed Stream Pressure field, type the steam pressure.
6. If you previously selected a soaker drum, in the Drum Volume field,
type the soaker drum volume.
Notes:
o
The steam stream is created internally and does not need to be created
on the flowsheet.
If you opted to add a soaker drum to the visbreaker, the Drum Outlet
Temperature and Theoretical Drum Outlet Temperature appear
on this page. The Theoretical Drum Temperature is calculated using
the other input variables specified on this page. The Drum Temperature is calculated from the Theoretical Drum Temperature
and the heat loss calculated from calibration. If you have not yet run a
calibration for your model, both fields will contain the same value.
Once you have typed all the necessary Input information, the model solves
using the default set of tuning factors.
622
Feed properties input from stream: includes the properties that the
visbreaker reads from the stream that it needs to calculate the kinetic
lumps that it uses. The properties are Specific Gravity, Sulfur Content,
Conradson Carbon Content, Nitrogen Content and D2887 9 point distillation.
Feed properties calculated from stream: HYSYS takes the properties listed in the Feed properties input from stream section and
calculates properties more directly related to the kinetic lumps: Watson
K, and from the Watson K estimates Paraffins, Naphthenes, and Aromatics.
Feed lump composition (wt%): HYSYS uses the Paraffins, Naphthenes and Aromatics, along with the distillation and the Conradson Carbon Content, to calculate the kinetic lumps going into the visbreaker.
14 Visbreaker
Volume Flowrate
Mass Flow
Volume Yields
Mass Yields
The mass and volume yields are the percentage of total feed to the visbreaker.
The volume flow and volume yield of Fuel Gas is on an FOE basis.
Specific Gravity
Sulfur
Nitrogen
Heat Load
Crack to Naphtha
Cracking Activity
Crack to H2S
In the Property Factors section, you can edit the following factors if desired:
l
Sulfur Parameters
SG Parameters
Nitrogen Parameters
Note: The Sulfur and Nitrogen parameters are multipliers and should always have positive values. If the Sulfur or Nitrogen parameter has a negative value, check your data
entry. The SG factor is an additive parameter and can have a positive or negative value.
For more details regarding these equations, refer to Visbreaker Equations.
14 Visbreaker
623
Notes
Using the Notes page on the Simulation tab, you can add notations for the Visbreaker.
624
14 Visbreaker
-andl
Composition
14 Visbreaker
625
SG
Sulfur
Nitrogen
5. Once you are satisfied with the calibration, click the Transfer to Simulation button if you want to transfer the calibration data to simulation.
If you must add more information in order to calibrate, a message indicating the missing information appears in the Calibration Status section
of the Calibration Targets page.
The updated factors appear on the Tuning Parameters page of the Simulation tab, and the visbreaker simulation model automatically resolves.
Calibration Results
On the Calibration Result page of the Calibrate tab, you can view calibration
factors and cut measurements. You can also transfer calibration data to simulation using the Transfer to Simulation button.
In the Calibration Factors section, results for the following appear:
l
Crack to Naphtha
Cracking to LCO
Cracking to Gasoil
Cracking Activity
Crack to H2S
Sulfur Parameters
SG Parameters
Nitrogen
The Feed, Product, and Closure results for Mass Flow, Sulfur, and Nitrogen appear.
626
Sulfur to hydrocarbon cracking ratio: How reactive nonring sulfur is in comparison to hydrocarbons. The default value
is 1.1, meaning that non-ring sulfur is 10% more reactive than
hydrocarbons.
14 Visbreaker
Furnace Activity: Increasing the cracking activity in the furnace decreases cracking in the soaker drum to match targets.
Sulfur
Specific Gravity
Nitrogen
Temperature
Sulfur Content
Nitrogen Content
ConCarbon Content
Specific Gravity
Olefins [%]
Naphthenes [%]
Aromatics [%]
CloudPoint
RON
MON
Note: Click the Restore Defaults button to return to the default values.
Visbreaker Worksheet
14 Visbreaker
627
Conditions
On the Conditions page of the Worksheet tab, you can view and edit some of
the following conditions for the inlet and outlet streams:
l
Vapor
Temperature
Pressure
Molar Flow
Mass Flow
Molar Enthalpy
Molar Entropy
Heat Flow
Properties
On the Properties page of the Worksheet tab, you can edit the properties of
the inlet and outlet streams.
Composition
On the Composition page of the Worksheet tab, you can edit the composition
of the inlet and outlet streams.
Visbreaker Solver
Simulation Engine
On the Simulation Engine page of the Solver tab for the Visbreaker, you can
type EO commands to the engine directly.
1. In the Enter Script Command field, type an EO command.
2. From the Solve Failure Recovery Option drop-down list, select one
of the following options:
o
Do Nothing
Reset Variables
Restore Variables
Solver Settings
On the Solver Settings page of the Solver tab for the Visbreaker, you can
change EO settings, such as number of iterations and creep steps.
628
14 Visbreaker
4. In the Creep Iterations field, adjust the number of iterations to perform creep steps. The default value is 10.
5. In the Step Size field, type the step size with creep iterations as a fraction of the full step size. The default value is 0.1.
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
Presolve Commands
Using the Presolve Commands page on the Solver page, you can specify
commands to run before the EO solution.
Click Clear All to return to the default settings.
Postsolve Commands
Using the Postsolve Commands page on the Solver tab, you can specify commands to run after the EO solution.
Click Clear All to return to the default settings.
14 Visbreaker
629
630
14 Visbreaker
15 Naphtha Hydrotreater
The Naphtha Hydrotreater (NHT) unit operation is used to pretreat feeds going
to the Reformer or Isomerization unit. The NHT is typically located upstream of
the naphtha reformer. The main purpose is to remove sulfur, but it also
removes most of the olefins and nitrogens. It can be used to simulate naphtha
hydrotreating in your HYSYS PFD and can also be calibrated to match plant
data.
The reactor is modeled as a packed bed with vapor phase fluid. Kinetics are
coded using EORXR models similar to what has been implemented for Hydrocracker, Isomerization, and Reformer. It models hydrogen desulfurization
(HDS), hydrogen denitrogenation (HDN) and olefin saturation reactions. All of
the reactions follow LHHW rate laws.
For information regarding the Kinetic Lumps, refer to NHTKinetic Lumps.
Simulation
Major Simulation Inputs
l
HDS Activity
HDN Activity
Hydrogenation Activity
Other factors:
o
15 Naphtha Hydrotreater
631
Sulfur Removal
Nitrogen Removal
Olefin Saturation
Calibration
Calibration requires all of the same inputs as simulation, except for the kinetic,
property, and miscellaneous coefficients highlighted above.These are calculated by the calibration case.In order to calculate these coefficients and
factors, the calibration requires some product data.
632
H2
5N5
24DMC5
SBP8
6N9
P13
SU5
N2
P1
22DMC4
MBP7
NP8
IP10
N13
SU7
O2
P2
23DMC4
2MC6
O8
NP10
A13
SU8
CO
OL2
MBP6
3MC6
5N8
5N10
P14
NH3
CO2
P3
2MC5
3EC5
ETHYLBEN
A10
N14
NIT4
O3
3MC5
SBP7
O-XYLENE
6N10
A14
NIT5
IP4
SBP6
NP7
M-XYLENE
IP11
COKE
BNIT5
NP4
NP6
O7
P-XYLENE
NP11
H2O
BNIT6
P4
O6
DMCP
A8
5N11
H2S
DIOL4
O4
5N6
ECP
6N8
A11
TH4
DIOL5
IP5
A6
5N7
IP9
6N11
TH5
O9
NP5
6N6
A7
NP9
P12
TH6
O10
P5
22DMC5
6N7
5N9
N12
TH7
O11
O5
23DMC5
MBP8
A9
A12
SU3
O12
15 Naphtha Hydrotreater
15 Naphtha Hydrotreater
633
Sulfur Content
Nitrogen Content
Paraffins
Olefins
Naphthenes
Aromatics
where:
634
E
R 1 / T 1/ T
ref )
e (
.
kfwd = kref *
P H2
ref
= 600K.
15 Naphtha Hydrotreater
P H 2S
AROM
SUL
OLEF
HDN reaction:
r=
kfwd * Pa * P H 2n
1 + K _ SAT _ H 2 * P H 2 + K _ SAT _ AROM * PAROM + K _ SAT _ SUL * PSUL + K _ SAT _ OLEF * POLEF
where:
E
R 1 / T 1/ T
ref )
e (
.
kfwd = kref *
P H2
ref
= 600K.
AROM
SUL
OLEF
r=
kfwd * Pa * P H 2n
1 + K _ SAT _ H 2 * P H 2 + K _ SAT _ AROM * PAROM + K _ SAT _ SUL * PSUL + K _ SAT _ OLEF * POLEF
where:
E
R 1 / T 1/ T
ref )
e (
.
kfwd = kref *
ref
= 600K.
15 Naphtha Hydrotreater
635
P H2
AROM
SUL
OLEF
HDN reactions
O4 + H2 => P4
O5 + H2 => P5
O6 + H2 => NP6
O7 + H2 => NP7
O8 + H2 => NP8
O9 + H2 => NP9
Note: For the activation energy, Ea/1000R is unitless. It is the activation energy divided
by 1000R where R is that gas constant.
In HDS Adsorption Factors field, you can specify adsorption factor of H2, Aromatics, Organic Sulfur, Olefins and H2S on HDS sites.
In Saturation Adsorption Factors field, you can specify adsorption factor of
H2, Aromatics, Organic Sulfur and Olefins on saturation sites.
In H Power Factors field, you can specify the power of H2 partial pressure
2
on HDS, HDN, Olefin Saturation and Di-Olefin saturation reactions.
636
15 Naphtha Hydrotreater
Notes
Using the Notes page on the Simulation tab, you can enter notations for the
naphtha hydrotreater.
Description
Red
Yellow
The calibration has not yet been run, there was an issue with the most recent
calibration attempt, or that calibration was successful but the factors have not
yet been transferred to the simulation page.
Green
The calibration run was successful and the calibrated factors are consistent
with those on the Simulation page.
Running Calibration
When the status turns to yellow and "Calibration Data Entered. Ready to Run
Calibration" message appears, you can run calibration.
To run calibration:
15 Naphtha Hydrotreater
637
Calibration Input
Mechanical Input
Temperature
Reactor Diameter
Pressure
Catalyst Loading
Mass Flow
Catalyst Density
Sulfur Content
Nitrogen Content
Olefins Content
Kinetic Factors
The NHT calibration will calculate new kinetic factors. You can edit the kinetic
factor, if desired. However, it is only when the user clicks the transfer to simulation that the new factors are set in simulation.
To view and edit kinetic factors:
1. Click the Calibration tab.
2. Click the Kinetic Factors page.
Worksheet Tab
The Worksheet tab presents a summary of the information in the unit operation. The Worksheet tab provides access to the streams attached to the unit.
The displayed information is automatically updated as conditions change.
Stream Conditions
This page lets you define streams that are incomplete, or modify stream values
if you require changes in the simulation. Any blue colored value may be modified. This lets you easily define or modify a stream without opening the property view of each stream that is attached to the unit operation. This page also
lets you quickly see how the streams connected to the unit operation are acting
throughout the simulation.
Stream Properties
This page lets you quickly see how the streams connected to the unit operation
are acting throughout the simulation. Any value that is blue in color indicates
638
15 Naphtha Hydrotreater
that the value may be modified. Any changes made to this page are reflected in
the streams property view.
Stream Compositions
This page lets you define or modify the composition of streams attached to the
unit operation. Any value that is blue in color indicates that the value may be
modified. This lets you easily define or modify a streams composition without
opening the property view of each stream that is attached to the unit operation.
When you define or modify a composition, the Input Composition property view
property view appears. Any changes made to this page are reflected in the
streams property view.
Solver Tab
Simulation Engine
The Simulation Engine page of the Solver tab allows you to enter OOMF
script language commands for special tasks. For instance, you can print or
retrieve a particular variable. For more advanced usage, you can use the simulation engine for troubleshooting, or changing advanced options such as solver
tolerances.
Some examples of OOMF script command:
l
The following table describes the objects available on the Simulation Engine
page.
Button
Description
Clear Messages
Clears all the existing messages in the OOMF script commands window.
Update
Messages
Checks for new simulation messages and appends them to the messages
that are already in the OOMF script commands window.
Get Pre.
Command
Run Command
Solve
HYSYS
15 Naphtha Hydrotreater
639
In the History Size Lines field, enter the line number showing in the OOMF
Simulation Engine Messages and Script Commands field.
In the Solve Failure Recovery Options field, you can select one of the following action in case of failure:
l
Do Nothing
Solver Settings
On the Solver Settings page of the Solver tab, you can change EO settings,
such as number of iterations and creep steps.
Settings
Description
Convergence
Tolerance
Maximum Iterations
Minimum Iterations
Contains three fields that enable you to configure the creep function of the Solver:
l
Creep Steps On check box. Select On (enable) or Off (disable) option for the creep feature.
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
Presolve Commands
Using the Presolve Commands page on the Solver tab, you can specify commands to run before the EO solution.
640
15 Naphtha Hydrotreater
Postsolve Commands
Using the Postsolve Commands page on the Solver tab, you can specify commands to run after the EO solution.
Click Clear All to return to the default settings.
15 Naphtha Hydrotreater
641
642
15 Naphtha Hydrotreater
The CatGas Hydrotreater (CGHT) is used to treat the naphtha coming from an
FCC. The purpose is to remove sulfur and minimize olefin loss to prevent loss of
octane. The CGHT SHU (Selective Hydrogenation Unit) is typically the first
reactor in the Cat Gas treating process. The Cat Gas treating process treats the
effluent from the Catalytic Cracker (FCC). This process is also known as PrimeG. It runs at a much lower temperature and hydrogen concentration than CGHT
HDS. The first reactor in this process (SHU) is designed to remove diolefins and
convert light mercaptans to heavy mercaptans while maintaining high octane,
creating a sulfur-free light end cut that gets separated from the effluent before
the effluent is fed into the second unit, which performs a more standard desulfurization. It also it converts some light sulfides to heavier sulfides.
The reactor is modeled as a packed bed reaction with vapor phase fluid. Kinetics is coded using EORXR models similar to what has been implemented for
Hydrocracker, Isomerization, and Reformer. It models hydrogen desulfurization (HDS), Di-Olefin Saturation and Olefin saturation reactions.
For information regarding the Kinetic Lumps, refer to CGHT SHUKinetic Lumps.
Simulation
Major Simulation Inputs
l
HDS Activity
HDN Activity
Hydrogenation Activity
Other factors:
643
Di-olefin Saturation
Olefin Saturation
Calibration
Calibration requires all of the same inputs as simulation, except for the kinetic,
property, and miscellaneous coefficients highlighted above.These are calculated by the calibration case.In order to calculate these coefficients and
factors, the calibration requires some product data.
644
H2
5N5
24DMC5
SBP8
6N9
P13
SU5
N2
P1
22DMC4
MBP7
NP8
IP10
N13
SU7
O2
P2
23DMC4
2MC6
O8
NP10
A13
SU8
CO
OL2
MBP6
3MC6
5N8
5N10
P14
NH3
CO2
P3
2MC5
3EC5
ETHYLBEN
A10
N14
NIT4
O3
3MC5
SBP7
O-XYLENE
6N10
A14
NIT5
IP4
SBP6
NP7
M-XYLENE
IP11
COKE
BNIT5
NP4
NP6
O7
P-XYLENE
NP11
H2O
BNIT6
P4
O6
DMCP
A8
5N11
H2S
DIOL4
O4
5N6
ECP
6N8
A11
TH4
DIOL5
IP5
A6
5N7
IP9
6N11
TH5
O9
NP5
6N6
A7
NP9
P12
TH6
O10
P5
22DMC5
6N7
5N9
N12
TH7
O11
O5
23DMC5
MBP8
A9
A12
SU3
O12
CatGas
HydrotreaterSHUProperty
View
Simulating the CatGas Hydrotreater SHU
Specifying Input
To specify input:
1. On the Input page of the Simulation tab, from the Feed H2 + Naphtha and Effluent drop-down lists, specify the inlet and outlet streams.
2. In the Name field, edit the name, if desired.
3. Specify Internal Diameter.
645
Diolefins Content
Paraffins Content
Olefins Content
Naphthenes Content
Aromatics Content
r=
kfwd * Pa * P H 2n
1 + K _ SAT _ H 2 * P H 2 + K _ SAT _ AROM * PAROM + K _ SAT _ SUL * PSUL + K _ SAT _ OLEF * POLEF
where:
646
kfwd = kref *
ref
E
R 1 / T 1/ T
ref )
e (
.
= 600K.
P H2
AROM
SUL
OLEF
r=
kfwd * Pa * P H 2n
1 + K _ SAT _ H 2 * P H 2 + K _ SAT _ AROM * PAROM + K _ SAT _ SULF * PSULF + K _ SAT _ OLEF * POLEF
where:
l
P H2
AROM
SUL
OLEF
647
In the Kinetic Factors page Simulation tab, you can specify each reaction
activation energy and reference rate, you can edit following activation energy
and reference rate if desired:
HDS reactions
O4 + H2 => P4
O5 + H2 => P5
O6 + H2 => NP6
O7 + H2 => NP7
O8 + H2 => NP8
O9 + H2 => NP9
Note: For the activation energy, Ea/1000R is unitless. It is the activation energy divided
by 1000R where R is the gas constant.
In HDS Adsorption Factors field, you can specify adsorption factor of H2, Aromatics, Organic Sulfur, Olefins and H2S on HDS sites.
In Saturation Adsorption Factors field, you can specify adsorption factor of
H2, Aromatics, Organic Sulfur and Olefins on saturation sites.
In H2 Power Factors field, you can specify the power of H2 partial pressure
on HDS, HDN, Olefin Saturation and Di-Olefin saturation reactions.
648
Note: All pages in the Calibration tab have a calibration status bar, showing the existing
state of the calibration:
l
Yellow: The calibration has not yet been run, there was an issue with the most
recent calibration attempt, or that calibration was successful but the factors have
not yet been transferred to the simulation page.
Green: The calibration run was successful and the calibrated factors are consistent
with those on the Simulation page.
Specifying ProductData
The Product page on the Calibration tab lists the following calibration targets
- Light Sulfur content, PONA basis, Olefins content, and Di-Olefin content. You
can specify those targets.
Running Calibration
When the status bar turns to yellow and the "Calibration Data Entered. Ready to
Run Calibration" message appears, you can run calibration.
To run calibration:
1. Click the Calibration tab.
2. Click the Run Calibration page.
3. Click Run Calibration.
4. Click Transfer Factors To Simulation to transfer calibration factors
to simulation, if desired.
You can view following information in Run Calibration page:
649
Calibration Factors
Calibration Input
Mechanical Input
Temperature
Reactor Diameter
Pressure
Catalyst Loading
Mass Flow
Catalyst Density
Diolefin Content
Olefins Content
Solver Tab
Simulation Engine
The Simulation Engine page of the Solver tab allows you to enter OOMF
script language commands for special tasks. For instance, you can print or
retrieve a particular variable. For more advanced usage, you can use the simulation engine for troubleshooting, or changing advanced options such as solver
tolerances.
Some examples of OOMF script command:
l
The following table describes the objects available on the Simulation Engine
page.
Button
Description
Clear Messages
Clears all the existing messages in the OOMF script commands window.
Update
Messages
Checks for new simulation messages and appends them to the messages
that are already in the OOMF script commands window.
Get Pre.
Command
Run Command
Solve
HYSYS
In the History Size Lines field, enter the line number showing in the OOMF
Simulation Engine Messages and Script Commands field.
650
In the Solve Failure Recovery Options field, you can select one of the following action in case of failure:
l
Do Nothing
Solver Settings
On the Solver Settings page of the Solver tab, you can change EO settings,
such as number of iterations and creep steps.
Settings
Description
Convergence
Tolerance
Maximum Iterations
Minimum Iterations
Contains three fields that enable you to configure the creep function of the Solver:
l
Creep Steps On check box. Select On (enable) or Off (disable) option for the creep feature.
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
Presolve Commands
Using the Presolve Commands page on the Solver tab, you can specify commands to run before the EO solution.
Click Clear All to return to the default settings.
651
Postsolve Commands
Using the Postsolve Commands page on the Solver tab, you can specify commands to run after the EO solution.
Click Clear All to return to the default settings.
652
The CatGas Hydrotreater (CGHT) is used to treat the naphtha coming from an
FCC. The purpose is to remove sulfur and minimize olefin loss to prevent loss of
octane. Usually, there is a column after the FCC, which separates the light and
heavy naphtha. Typically, only the heavy naphtha will go to the CatGas Hydrotreater Hydro-Desulfurization (CGHTHDS). The CGHTHDS is typically the
second reactor in the CatGas treating process. The Cat Gas treating process
treats the effluent from the Catalytic Cracker (FCC). This process is also known
as Prime-G.
The reactor is modeled as a packed bed reaction with vapor phase fluid. Kinetics is coded using EORXR models similar to what has been implemented for
Hydrocracker, Isomerization, and Reformer. It models hydrogen desulfurization (HDS), hydrogen denitrogenation (HDN) and Olefin saturation reactions. All of the reactions follow LHHW rate laws.
For information regarding the Kinetic Lumps, refer to CGHT HDS Kinetic Lumps.
Simulation
Major Simulation Inputs
l
HDS Activity
HDN Activity
Hydrogenation Activity
Other factors:
653
Sulfur Removal
Nitrogen Removal
Olefin Saturation
Calibration
Calibration requires all of the same inputs as simulation, except for the kinetic,
property, and miscellaneous coefficients highlighted above.These are calculated by the calibration case.In order to calculate these coefficients and
factors, the calibration requires some product data.
654
H2
5N5
24DMC5
SBP8
6N9
P13
SU5
N2
P1
22DMC4
MBP7
NP8
IP10
N13
SU7
O2
P2
23DMC4
2MC6
O8
NP10
A13
SU8
CO
OL2
MBP6
3MC6
5N8
5N10
P14
NH3
CO2
P3
2MC5
3EC5
ETHYLBEN
A10
N14
NIT4
O3
3MC5
SBP7
O-XYLENE
6N10
A14
NIT5
IP4
SBP6
NP7
M-XYLENE
IP11
COKE
BNIT5
NP4
NP6
O7
P-XYLENE
NP11
H2O
BNIT6
P4
O6
DMCP
A8
5N11
H2S
DIOL4
O4
5N6
ECP
6N8
A11
TH4
DIOL5
IP5
A6
5N7
IP9
6N11
TH5
O9
NP5
6N6
A7
NP9
P12
TH6
O10
P5
22DMC5
6N7
5N9
N12
TH7
O11
O5
23DMC5
MBP8
A9
A12
SU3
O12
655
Sulfur Content
Nitrogen Content
Paraffins Content
Olefins Content
Naphthenes Content
Aromatics Content
where:
656
E
R 1 / T 1/ T
(
)
ref
e
.
kfwd = kref *
P H2
P H 2S
ref
= 600K.
AROM
SUL
OLEF
HDN reaction:
r=
kfwd * Pa * P H 2n
1 + K _ SAT _ H 2 * P H 2 + K _ SAT _ AROM * PAROM + K _ SAT _ SUL * PSUL + K _ SAT _ OLEF * POLEF
where:
E
R 1/ T 1/ T )
ref
* e (
.
kfwd = kref
P H2
ref
= 600K.
AROM
SUL
OLEF
657
r=
kfwd * Pa * P H 2n
1 + K _ SAT _ H 2 * P H 2 + K _ SAT _ AROM * PAROM + K _ SAT _ SUL * PSUL + K _ SAT _ OLEF * POLEF
where:
l
P H2
AROM
SUL
OLEF
HDN reactions
O4 + H2 => P4
O5 + H2 => P5
O6 + H2 => NP6
O7 + H2 => NP7
O8 + H2 => NP8
O9 + H2 => NP9
Note: For the activation energy, Ea/1000R is unitless. It is the activation energy divided
by 1000R where R is that gas constant.
In HDS Adsorption Factors field, you can specify adsorption factor of H , Aro2
matics, Organic Sulfur, Olefins and H S on HDS sites.
2
658
In H Power Factors field, you can specify the power of H partial pressure
2
2
on HDS, HDN, Olefin Saturation and Di-Olefin saturation reactions.
Description
Red
Yellow
The calibration has not yet been run, there was an issue with the most recent
calibration attempt, or that calibration was successful but the factors have not
yet been transferred to the simulation page.
Green
The calibration run was successful and the calibrated factors are consistent
with those on the Simulation page.
If you are defining the feed type as an assay, you can check Use GC
Data to enter the GC data and have it calculated.
659
If you are using the GC feed type, you can click Pull Data From
Stream to copy the feed stream composition to the GC data table.
When finished, you can define the calibration product, and the run the calibration.
Running Calibration
When the status bar turns to yellow and the "Calibration Data Entered. Ready to
Run Calibration" message appears, you can run calibration.
To run calibration:
1. Click the Calibration tab.
2. Click the Run Calibration page.
3. Click Run Calibration.
4. Click Transfer Factors To Simulation to transfer calibration factors
to simulation, if desired.
You can view following information in Run Calibration page:
Calibrated Factors
Calibration Input
Mechanical Input
Temperature
Reactor Diameter
Pressure
Catalyst Loading
Mass Flow
Catalyst Density
Sulfur Content
Nitrogen Content
Olefins Content
660
Solver Tab
Simulation Engine
The Simulation Engine page of the Solver tab allows you to enter OOMF
script language commands for special tasks. For instance, you can print or
retrieve a particular variable. For more advanced usage, you can use the simulation engine for troubleshooting, or changing advanced options such as solver
tolerances.
Some examples of OOMF script command:
l
The following table describes the objects available on the Simulation Engine
page.
Button
Description
Clear Messages
Clears all the existing messages in the OOMF script commands window.
Update
Messages
Checks for new simulation messages and appends them to the messages
that are already in the OOMF script commands window.
Get Pre.
Command
Run Command
Solve
HYSYS
In the History Size Lines field, enter the line number showing in the OOMF
Simulation Engine Messages and Script Commands field.
In the Solve Failure Recovery Options field, you can select one of the following action in case of failure:
l
Do Nothing
661
Solver Settings
On the Solver Settings page of the Solver tab, you can change EO settings,
such as number of iterations and creep steps.
Settings
Description
Convergence
Tolerance
Maximum Iterations
Minimum Iterations
Contains three fields that enable you to configure the creep function of the Solver:
l
Creep Steps On check box. Select On (enable) or Off (disable) option for the creep feature.
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
Presolve Commands
Using the Presolve Commands page on the Solver tab, you can specify commands to run before the EO solution.
Click Clear All to return to the default settings.
Postsolve Commands
Using the Postsolve Commands page on the Solver tab, you can specify commands to run after the EO solution.
Click Clear All to return to the default settings.
662
663
664
18 Alkylation Unit
The Aspen HYSYS Alkylation Units each model the same process, but with
either HF or H SO as the acid catalyst. There are 49 pure components and 55
2
4
reactions modeled in this unit. The alkylation unit treats the acid as an internal
catalyst and does not model the acid as an external stream.
The alkylation unit models are used to produce high-octane, gasoline-range
alkylate by alkylating isobutane with low molecule weight alkenes to produce
iso-octane (octane rating of 100) and other high-octane compounds, using HF
or H SO . HF or H2SO4 acid is used as catalyst to react C3-C5= with iC4. C4=
2
4
is the most advantageous olefin feedstock (with regards to yield, operation,
and acid consumption.) HF alkylation is more flexible but has greater safety
concerns.
They are modeled as CSTRs, and are isothermal, assuming kinetics are not limited by the acid. The acid itself is treated as a catalyst and is not represented by
a component in the component slate of the model.
PROPANE
2-METHYL-1,3-BUTADIENE
2,2,3-TRIMETHYLHEXANE
PROPYLENE
2,3-DIMETHYL-BUTANE
2,2,4-TRIMETHYLHEXANE
ISOBUTANE
2-METHYL-PENTANE
2,2,3,4-TETRAMETHYLPENTANE
N-BUTANE
3-METHYL-PENTANE
2,3-DIMETHYLNONANE
1-BUTENE
2,2-DIMETHYLPENTANE
2,3-DIMETHYLDECANE
TRANS-2-BUTENE
2,3-DIMETHYLPENTANE
2,3-DIMETHYLUNDECANE
CIS-2-BUTENE
2,4-DIMETHYLPENTANE
2,3-DIMETHYLDODECANE
ISOBUTYLENE
2-METHYLHEXANE
HYDROGEN-FLUORIDE
1,3-BUTADIENE
3-METHYLHEXANE
SULFURIC-ACID
N-PENTANE
2,3-DIMETHYLHEXANE
WATER
2-METHYL-BUTANE
2,4-DIMETHYLHEXANE
1-PENTENE
2,5-DIMETHYLHEXANE
18 Alkylation Unit
665
TRANS-2-PENTENE
2,2,3-TRIMETHYLPENTANE
CIS-2-PENTENE
2,2,4-TRIMETHYLPENTANE
2-METHYL-1-BUTENE
2,3,4-TRIMETHYLPENTANE
3-METHYL-1-BUTENE
2,3,3-TRIMETHYLPENTANE
2-METHYL-2-BUTENE
2,2-DIMETHYLHEPTANE
Feedstocks
l
HF or H SO (purchased catalyst)
2
Products
l
LPG-grade nC3
nC4 liquid
C5+ alkylate
Simulation
Major Simulation Inputs
666
18 Alkylation Unit
Other factors
o
Product yields:
o
Alkylate Properties:
o
Calibration
Calibration requires all of the same inputs as simulation, except for the kinetic,
property, and miscellaneous coefficients highlighted above.These are calculated by the calibration case.In order to calculate these coefficients and
factors, the calibration requires some product data.
AlkylationProcess
Process Information
l
Settler removes acid from alkylate for recycle (make-up acid required)
ReactionTemp, F
18 Alkylation Unit
HF
H SO
Effect
60-115
35-60
667
80-95
88-95
30-80
40-80
HC ContactTime, min
8-20
20-30
Propylene
Butylene
Pentylene
171-178
170-178
197-220
119-132
110-117
96-113
34-42
13-25
25-42
RVP, psi
3.8
2.6
4.0
MONC
88-90
92-94
88-93
RONC
89-92
94-98
90-92
H2SO4 AlkylationUnit
668
18 Alkylation Unit
or
18 Alkylation Unit
669
Viewing Results
The Results page on the Simulation tab reports the following Yields and
Alkylate properties:
Yields:
l
Propane Content
Butane Content
Isobutane Content
Alkylate Properties listed only for the C5+ portion of the product stream:
l
RON(Clear)
MON(Clear)
D86 0%
D86 5%
D86 10%
D86 30%
D86 50%
D86 70%
D86 90%
D86 95%
D86 100%
l
l
670
C7 to C14 activities affect the primary and secondary alkylation reactions that form C7 through C14 paraffins.
The hydrogen transfer activity affects all hydrogen transfer reactions.
The n-Butane activity affects the hydrogen transfer reactions that form
normal butane.
The n-Pentane activity affects the hydrogen transfer reactions that form
18 Alkylation Unit
normal pentane.
l
The Propane activity affects the hydrogen transfer reactions that form
propane.
The global activity affects all of the reactions.
Description
C6
2-3-Dimethylbutane
2-Methylpentane
3-Methylpentane
2-2-Dimethylpentane
2-3-Dimethylpentane
2-4-Dimethylpentane
2-Methylhexane
3-Methylhexane
2-3-Dimethylhexane
2-4-Dimethylhexane
2-5-Dimethylhexane
2-2-3-Trimethylpentane
2-2-4-Trimethylpentane
2-3-4-Trimethylpentane
2-3-3-Trimethylpentane
2-2-Dimethylheptane
2-2-3-Trimethylhexane
2-2-4-Trimethylhexane
2-2-3-4-Tetramethylpentane
C7
C8
C9
18 Alkylation Unit
671
C7BP +
propene ->
C10BP
C8BP +
propene ->
C11BP
tr2-butene +
isobutane =>
C8BP
C9BP +
propene ->
C12BP
cis2-butene +
isobutane =>
C8BP
2M-1-Butene +
isobutane =>
C9BP
3M-1-Butene +
isobutane -> C9BP
2M-2-Butene +
isobutane -> C9BP
tr2-Pentane +
isobutane =>
C9BP
cis2-Pentane +
isobutane =>
C9BP
1,3-butadiene +
2*isobutane =>
C12BP
isoprene +
2*isobutane =>
C13BP
672
18 Alkylation Unit
All of the reactions follow stoichiometric rate laws. It is assumed a large excess
of acid catalyst and all reactions have two reactants. The rate for each reaction
with two reactant molecules is calculated by:
r = k C a Cb
where:
l
k = A * e( RT )
Ea
A Propylene Dimerization reaction also occurs. This reaction has three reactant
molecules and contains both an alkylation and a hydrogen transfer:
r = k C a2 Cb
To edit Kinetic Factors:
1. Click the Simulation tab.
2. Click the Kinetic Factors page.
3. Edit Ea/(1000*R) and ln(A), if desired.
Note: For the activation energy, Ea/1000R is unitless. It is the activation energy divided
by 1000R where R is the gas constant.
Notes
Using the Notes page on the Simulation tab, you can enter notations for the
Alkylation Unit.
18 Alkylation Unit
673
Description
Red
Yellow
The calibration has not yet been run, there was an issue with the most recent
calibration attempt, or that calibration was successful but the factors have not
yet been transferred to the simulation page.
Green
The calibration run was successful and the calibrated factors are consistent
with those on the Simulation page.
Temperature
Pressure
674
18 Alkylation Unit
Mass Flow
-or-
Composition
Specifying Alkylates
On the Alkylates page of the Calibration tab, you can specify the properties
of the Alkylate streams. You can add more than 1 alkylate stream, but no more
than 3.
Enter values for following:
l
Mass Rate
Volume Rate
Temperature
Pressure
Distillation Data
Density
RON(Clear)
MON(Clear)
Running Calibration
When the status bar turns to yellow and the "Calibration Data Entered. Ready to
Run Calibration" message appears, you can run calibration.
To run calibration:
1. Click the Calibration tab.
2. Click the Run Calibration page.
3. Click Run Calibration.
18 Alkylation Unit
675
Reaction Activities
Split Factors
Solver Tab
Simulation Engine
The Simulation Engine page of the Solver tab allows you to enter OOMF
script language commands for special tasks. For instance, you can print or
retrieve a particular variable. For more advanced usage, you can use the simulation engine for troubleshooting, or changing advanced options such as solver
tolerances.
Some examples of OOMF script command:
l
The following table describes the objects available on the Simulation Engine
page.
676
Button
Description
Clear Messages
Clears all the existing messages in the OOMF script commands window.
Update
Messages
Checks for new simulation messages and appends them to the messages
that are already in the OOMF script commands window.
18 Alkylation Unit
Button
Description
Get Pre.
Command
Run Command
Solve
HYSYS
In the History Size Lines field, enter the line number showing in the OOMF
Simulation Engine Messages and Script Commands field.
In the Solve Failure Recovery Options field, you can select one of the following action in case of failure:
l
Do Nothing
Solver Settings
On the Solver Settings page of the Solver tab, you can change EO settings,
such as number of iterations and creep steps.
Settings
Description
Convergence
Tolerance
Maximum Iterations
Minimum Iterations
Contains three fields that enable you to configure the creep function of the Solver:
l
Creep Steps On check box. Select On (enable) or Off (disable) option for the creep feature.
The EO solver report files for reactor models are written to the Temp directory.
To access the solver report file:
1. Navigate to Users\username\AppData\Local\Temp (where username is your login name).
18 Alkylation Unit
677
2. To find the solver report file, sort the files by date, and select the most
recent file with an .atslv extension.
The solver report file indicates which equations are most open (both scaled and
unscaled) and which equations are most linear.
Presolve Commands
Using the Presolve Commands page on the Solver tab, you can specify commands to run before the EO solution.
Click Clear All to return to the default settings.
Postsolve Commands
Using the Postsolve Commands page on the Solver tab, you can specify commands to run after the EO solution.
Click Clear All to return to the default settings.
678
18 Alkylation Unit
19 Refining Transitions
Petroleum Transition
The Petroleum transition unit operation is used to convert one petroleum
stream to another petroleum stream with a different basis.
This option is available in the following places:
l
Basic Theory
For shared components, common property vectors are transferred as is from
the feed fluid package to the product fluid package. If any of the feed or
product property package is an Aspen Properties Property Package, then only
Molecular Weight, Liquid Density and all petroleum property vectors are transferred.
For hypo components in a product stream having only one pure/hypo component of feed, common property vectors are transferred as is from feed fluid
package to the product fluid package. If any of the feed or product property
packages is an Aspen Properties Property Package then only Molecular Weight,
Liquid Density and all petroleum property vectors are transferred.
For product stream hypo components defined by more than one feed component, average properties are calculated according to following rule:
1. Molecular weight is mixed by mole fraction.
2. 1/ Density is mixed by the mass blending rule.
3. Heat of formation and Heat of combustion is calculated by the mass
blending rule.
4. Ideal enthalpy coefficients are mixed by the mass blending rule.
5. Critical Temperature and Critical Pressure is mixed by a special mixing
19 Refining Transitions
679
Steps (3) to (9) will not be performed if the feed or product property package is
an Aspen Properties package.
If the feed or product stream uses an Aspen Properties property package, then
the remaining physical properties are estimated using molecular weight, density and boiling point.
The following Petroleum Properties are shifted to feed bulk values:
l
Cloud Point
Flash Point
Pour Point
MON (Clear)
RON (Clear)
MON (Leaded)
RON (Leaded)
References
Leibovici, C.F. 1993. A consistent procedure for the estimation of properties
associated to lumped systems. Fluid Phase Equilibria 87, 1993, 189-197.
Reid R.C., Prausnitz J.M., and Poling B.E. The properties of gases and liquids.
4th Ed., McGraw Hill Book Company, p. 83., 1987.
680
19 Refining Transitions
References
Leibovici, C.F. 1993. A consistent procedure for the estimation of properties
associated to lumped systems. Fluid Phase Equilibria 87, 1993, 189-197.
Reid R.C., Prausnitz J.M., and Poling B.E. The properties of gases and liquids.
4th Ed., McGraw Hill Book Company, p. 83., 1987.
19 Refining Transitions
681
References
Leibovici, C.F. 1993. A consistent procedure for the estimation of properties
associated to lumped systems. Fluid Phase Equilibria 87, 1993, 189-197.
Reid R.C., Prausnitz J.M., and Poling B.E. The properties of gases and liquids.
4th Ed., McGraw Hill Book Company, p. 83., 1987.
682
19 Refining Transitions
There is also some relative adjustment of the relative number of rings for aromatics and sulfur compounds based upon changes of the WABPs. Note that the
Ca ratio and Cn ratio are raised to a power equal to the fraction of aromatic carbons and the fraction of naphthenic carbons for a given compound. This means
that compounds which are more highly aromatic are more greatly affected than
compounds that are less aromatic.
References
Leibovici, C.F. 1993. A consistent procedure for the estimation of properties
associated to lumped systems. Fluid Phase Equilibria 87, 1993, 189-197.
Reid R.C., Prausnitz J.M., and Poling B.E. The properties of gases and liquids.
4th Ed., McGraw Hill Book Company, p. 83., 1987.
19 Refining Transitions
683
Reformer Transition
This transition was developed to convert a feed stream with any composition
and properties into Reformer kinetic lumps. This transition is available on the
stream cutter as well as the Reformer feed characterization page.
There are two ways to characterize the Reformer feed:
1. Specify Feed composition directly as Reformer kinetic lumps
2. Use properties to characterize Reformer kinetic lumps
In option 1, there is no calculation required.
In option 2, the following properties are required:
Minimum: Distillation, Paraffin Content (P), Naphthenic Content (N), Aromatic
Content (A)
Optional: Detailed GC analysis
It is also possible to characterize the Reformer feed from an assay where a
user just needs to specify the initial and final boiling points of the naphtha fraction of that assay. In this case properties will be generated from the assay.
When a process stream is used in a reformer transition, the stream properties
are used.
The PNA breakdown is used to ensure that the right amount of paraffins, naphthenics, and aromatics are in the feed. The distillation is used to break down
each of the paraffins, naphthenics, and aromatics by carbon number. The feed
type is used to set the various isomer ratios for the feed. Currently, there is
only a default feed type. If a you would like a ratio different from the default
you can create your own feed type and use that instead.
To create a new feed type, you can go to Library ply of the Feed Data tab in the
reformer environment (similar applies to FCC and Hydrocracker environment).
You can type new values for any of the ratios in the area entitled "Properties of
Selected Feed Type." You can export the feed type using the export button or
import a feed type using the import button. Note that if the reformer is already
completely specified, you should put HYSYS in holding mode to change multiple
values in the feed type.
Following is a description of each of the feed type properties:
684
Feed Type
Properties
IP5/Total C5
nP5/Total C5
22-Dimethyl-butane/Total P6
19 Refining Transitions
Feed Type
Properties
23-Dimethyl-butane/Total P6
2-Methyl-pentane/Total P6
3-Methyl-pentane/Total P6
Methyl-cyclopentane/[Methylcyclopentane+Cyclohexane]
22-Dimethyl-pentane/Total P7
23-Dimethyl-pentane/Total P7
24-Dimethyl-pentane/Total P7
33-Dimethyl-pentane/Total P7
223-Trimethyl-pentane/Total P7
2-Methyl-hexane/Total P7
3-Methyl-hexane/Total P7
Ethyl-pentane/Total P7
Dimethyl-cyclopentane/TotalN7
Ethyl-cyclopentane/Total N7
Normal P8/Total P8
MB P8/Total P8
N8 N5/[N5+N6 Ring]
IP9/Total P5
N9 N5/[N5+N6 Ring]
IP10/Total P10
IP11/Total P11
19 Refining Transitions
685
Feed Type
Properties
References
Leibovici, C.F. 1993. A consistent procedure for the estimation of properties
associated to lumped systems. Fluid Phase Equilibria 87, 1993, 189-197.
Reid R.C., Prausnitz J.M., and Poling B.E. The properties of gases and liquids.
4th Ed., McGraw Hill Book Company, p. 83., 1987.
686
19 Refining Transitions
Index
1
1-Pentene 290
2
2-Methyl-1-butene 290
2-Methyl-2-butene 290
2-methyl-3-ethylbenzene 210
21-lump 285, 320, 324
reviews 320
21-Lump Reaction Paths 288
3
3-dimethylhexane 209
3-dimethylpentane 209
3-methyl-1-butene 290
3-ring 315-316
4
4-dimethyl 209
5
5-trimethylcyclohexane 209
A
Activity
Feed/Effects 88
Add
water/chloride 90
advanced parameters
visbreaker 624
Afterburn 323
Air Blower Performance Curves 326
Ambient Temperature 326
Analysis 314, 319-320
API 325
Index
base curves
delayed coker 608
visbreaker 624
Base Reaction Rate Mechanisms 85
Base Temp 94
Base Temperature 94
Basic Nitrogen 325
Benzothiophene 207
Benzothiophenes 207
Blocks 320
FCC Reactor 320
Bulk Density 326
Burned 314
SOX 314
Butenes 289
C
C10H18-2 209
C10H20 213
C12-Cyclo-sulfide 212
C14 209
C14-tetrahydronaphthalene 210
C14H12 211
C14H20 210
C14H22 210
C14H24 209
687
C18-1ring-Arom 210
C18-naphthalene 210
C18-tetrahydronaphthalene 210
C18_OLEF 213
C18H24 210
C18H26 211
C18H28 210
C18H36 209
C18H38 209
C2 208
C21-1 209
C21-1-ring-cycloheaxane 209
C21-2 209
C21-2-ring-cycloheaxane 209
C21-3-ring-cycloheaxane 210
C21-3ring-Arom 211
C21-4-ring-cycloheaxane 210
C21H26S 212
C21H30 210
C21H33N 213
C21H40 209
C21H42 209
C26H54 209
C3 207
C35H55N 213
C3H8 208
C4 207, 289
C47H32 211
C47H76 211
C47H78 211
C47H86 210
C47H88 210
C4H10_2 209
C5 209, 286, 314, 319-320
430 286, 314
C5-430 314
C6 289, 319-320
C6-olef 213
C6 GC For All Light Materials 325
C6H12 209
C6H12-2 209
C6H6 210
C7-olef 213
C7H14 209
C8-Cyclo-sulfide 212
C8H10_3 210
C8H12-3 210
C8H16 209
C8N 209
688
C9H20_4 209
C9H7N 212
C9H9N 212
C9N 209
Calculates 96
Feed 96
reformate RVP 97
tubeskin 97
Calculation Blocks 86
calibrating
delayed coker 608
visbreaker 624
Calibration Data
export to simulation 442
save 443
Calibration Factors 443
Calibration Mode 318
calibration results
delayed coker 608
visbreaker 624
Calibration Run 318
product streams 515
regenerator 466
calibration targets
specifying for the delayed
coker 608
specifying for visbreaker 624
Carbon Number 86
Carbon Number Multipliers 85
Cat/oil 315-316
Resulting 316
Catalyst 90
add 549
catalyst oil ratio 464-465
circulation rate 465
clone 550
delete 550
dilute phase 416
edit 550
export blend 342, 462
import 551
Catalyst Activity
tuning factor 492
Catalyst Blend 342, 462
base 340-341, 402, 460
Catalyst Properties 326
Catalytic Reformer 69, 79, 83, 87,
91, 97-98, 102
Index
Index
Compressor Discharge 88
First Reactor Inlet Pressure 88
Condenser Duty 87
Conradson 314, 316, 325
Conradson Carbon Residue 492
Crack 313
H2S 313
Crackability 313
creep steps
delayed coker 613
visbreaker 628
Cut
recycling 333
Cutpoint 314
Cyclization 91, 286
during 91
Cyclo-pentane 290
Cyclo-pentene 290
D
D2887 325
Data 325
Debutanizer 319
Dehydrogenation 84, 88
delayed coker
about 597
calibrating 608
calibration results 609
composition 613
conditions 612
creep steps 613
editing base curves 612
editing tuning factors 607
EO equations 614
EO variables 614
equations 599
getting started with 604
properties 613
selecting product cuts 608
setting up 604
simulation engine 613
solver 613
solver settings 613
specifying advanced
parameters 611
specifying calibration targets 610
specifying connections 604
specifying heavy end cuts 609
689
690
Expansion 84, 88
F
F 285
FCC Reactor 279, 284-285, 313, 315,
317, 319-320, 327-330, 388
Blocks 320
Entering 313
Re-running 317
Feed / Product Definition
Differences 86
Feed Blends 324
Feed Libraries
add type 555, 570
clone type 556
delete type 556
edit type 556
export type 557
import type 557
Feed/Effects 88
Feed/Reactor 85
Feeds
Calculates 96
First Reactor Inlet Pressure 88
Compressor Discharge 88
FLMAP 97
Following 315
Arrhenius-type 315
Fractionator 286
Fractionator Key Parameters 344
Fresh Catalyst 326
Fresh Catalyst Makeup Rate 327
G
Gas Plant Data 326
Gasoils 324
Gasoline Lump C5 286
Geometries 327
GLC 288
Gravity 367
Groups 207
GSP 313
H
H2 319
H2HC 97
Index
Index
I
IC5 289
Inferentials 288
Injection 326
Inlet Pressure 88
Reactor 87
Inlet Temp 94
Iso-butane 207, 289
Iso-butene 290
Iso-paraffin 86
Iso-pentane 289
ISOMD1 96
ISOMD2 96
ISOMD3 96
Isomer
calibration run 290
Isomerization 83, 88, 91, 96, 585,
587-594
during 91
ISOMP4 96
ISOMP5 96
K
Kinetic coke 344, 492
catalyst 553
Kinetic Tuning
tuning factor 490
L
Last Reactor Inlet 88
Last Reactor Outlet 88
Last Reactor Inlet Pressure 88
Reactor 87
Last Reactor Outlet 88
Last Reactor Inlet 88
Product Separator 87
Laydown 90-91, 320
LCO 314, 319-320, 325
Lift Gas Rate 326
Lift Steam 326
Light 1-Ring Aromatics 286
light end cuts
visbreaker 624
Light Ends 325
Light Ends Distribution
tuning factor 490
Light Naphthenes 286
691
692
Index
Paths
Coke 91
Pentenes 289
Percent Heat Applied 9
Perform 322
DP 322
Permanent 90
Petroleum Distillation Column 25, 31
Petroleum Feeder 41-42
Petroleum Shift Reactor 169-170,
180
Ph 285, 315
Pl 285
Platinum 90
Polycyclic 91
Polycyclics 91
Polymerization 84, 88
Positions 324
postsolve commands
visbreaker 621
Pour Point 326
Pre-Calibrating
Catalytic Reformers 135
Hydrocrackers 244
presolve commands
visbreaker 621
Pressure on Reaction Mechanisms 88
Pressure Profile 326
Product Blender 47-48, 50-51, 53
Product Delumper 318
product properties
visbreaker 621
Product Separator 87
Last Reactor Outlet 88
product yields
visbreaker 621
Propane 289
Properties 324
property correlation multipliers 366
Propylene 288
PSEP 97
Pseudo-component 286
Pseudocomponents 314, 322
PSSPL 97
Pyrrole 212
Pyrrolidine 212
Index
Q
Quinoline 212
R
R 315
R/R 324
Ra1 287, 315
Ra2 287, 315
Ra3 287, 315
Ramsbottom 325
Ras 315
Rate
Aromatic 91
C6 91
RCMP2 97
Re-running 317
FCC Reactor 317
REACT_A 84, 96
factors 96
REACT_B 84, 96
REACT_C 84, 96
Reactant/product 285
Number 285
Reaction Type 83, 88
Reaction Type Multipliers 85
Reactor 87
Inlet Pressure 88
Last Reactor Inlet Pressure 88
Reactor Model
dilute phase 335-337, 384-385,
433-434, 451, 474-475, 501-502,
513-514
Reactor Section 87
Reactor Vessel 326
Reactor/heaters 80
Reboiler 95
Reboiler Duty 87
REC1AN 97
RECSPL 97
RECV 98
REFCTL 94, 96
Refining Operations 1, 25, 41, 47, 69,
169, 187, 279, 573, 585
REFMRVP 97
Reformate 95
Reformate RVP 97
Calculates 96
693
694
Simulation 314
Simulation Data
export to calibration 443
simulation engine
delayed coker 613
Simulation Mode 318
Simulation Run 318
Single riser 321
Sintering 90
Slide Valve 326
Slide Valve Delta P 326
solver
visbreaker 628
solver settings
delayed coker 613
visbreaker 628
Source Component 289
SOx
tuning factor 492
SOX 314, 319
Burned 314
Specify
Tray 11 95
Trays 10 95
specifying connections
delayed coker 604
visbreaker 621
specifying heavy end cuts
delayed coker 608
specifying input
delayed coker 604
visbreaker 621
specifying light end cuts
delayed coker 608
specifying postsolve commands
delayed coker 604
specifying presolve commands
delayed coker 604
Split 289
Split Out Components 290
Stabilizer 87
Stabilizer Bottoms MON 87
Stabilizer Bottoms RON 87
Steam Rate 326
Stripping 326
Steam/catalyst 317
Stoichiometric 94
Stripper 326
tuning factor 492
Index
Index
VAN2 211
VAN3 211
VANA 211
Vapor Entrainment 317
Variable Navigator 17
Vessel Heater 8
Vessels
duty parameters 8
heater type 8
kettle chiller 10
kettle heat exchanger 10
kettle reboiler 10
liquid heater 8
viewing product properties
delayed coker 604
viewing product yields
delayed coker 604
visbreaker
about 617
calibrating 624
calibration results 624
calibration targets 624
composition 628
conditions 628
creep steps 628
editing base curves 627
editing tuning parameters 623
EO equations 629
EO variables 629
equations 619
getting started with 621
Notes 622
product properties 623
product yields 623
properties 628
selecting product cuts 624
setting up 621
solver 628
solver settings 628
specifying advanced
parameters 626
specifying connections 621
specifying heavy end cuts 625
specifying input 622
specifying light end cuts 625
specifying postsolve
commands 624
specifying presolve commands 624
workflow 621
695
worksheet 627
VthA2N 212
W
WABT 87, 95
WAIT 87, 94, 97
Water/Chloride 90
Well-understood 285
Wet Gas Compressor Performance
Curves 326
WHSV 87, 97
Z
ZSM-5 Additive 341
calibration 461
ZSM-5 Content 326
696
Index